Method for fabricating surgical stapler anvils

ABSTRACT

Methods for fabricating an anvil for a surgical stapling device. Various methods include forming an anvil body from a first material and a deformable anvil tip from a second material and attaching the deformable anvil tip to a distal end of the anvil body with a deformable second attachment member. Other methods include molding a deformable anvil tip to a distal end of an anvil body.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation application claiming priority under35 U.S.C. § 120 to U.S. patent application Ser. No. 16/105,101, entitledMETHOD FOR FABRICATING SURGICAL STAPLER ANVILS, filed Aug. 20, 2018, nowU.S. Patent Application Publication No. 2020/0054323, the entiredisclosure of which is hereby incorporated by reference herein.

BACKGROUND

The present invention relates to surgical instruments and, in variousarrangements, to surgical stapling and cutting instruments and staplecartridges for use therewith that are designed to staple and cut tissue.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features of the embodiments described herein, together withadvantages thereof, may be understood in accordance with the followingdescription taken in conjunction with the accompanying drawings asfollows:

FIG. 1 is a perspective view of a powered surgical stapling system;

FIG. 2 is a perspective view of an interchangeable surgical shaftassembly of the powered surgical stapling system of FIG. 1;

FIG. 3 is an exploded assembly view of portions of a handle assembly ofthe powered surgical stapling system of FIG. 1;

FIG. 4 is an exploded assembly view of the interchangeable surgicalshaft assembly of FIG. 2;

FIG. 5 is another partial exploded assembly view of a portion of theinterchangeable surgical shaft assembly of FIG. 4;

FIG. 6 is another partial perspective view of an end effector portion ofthe interchangeable surgical shaft assembly of FIG. 2 with jaws thereofin an open position;

FIG. 7 is another perspective view of a portion of the end effector andinterchangeable shaft assembly of FIG. 6;

FIG. 8 is a perspective view of a distal closure member embodiment;

FIG. 9 is an end view of the distal closure member embodiment of FIG. 8;

FIG. 10 is a side elevational view of the end effector and portion ofinterchangeable surgical shaft assembly of FIG. 7, with an anvil and aclosure member thereof in a fully open position;

FIG. 11 is a cross-sectional view of the end effector and closure memberof FIG. 10, taken along line 11-11 in FIG. 10;

FIG. 12 is a side elevational view of the end effector and portion ofinterchangeable surgical shaft assembly of FIG. 11, with the anvil andclosure member in a closed position;

FIG. 13 is a cross-sectional view of the anvil and closure member ofFIG. 12, taken along line 13-13 in FIG. 12;

FIG. 14 is a side elevational view of the end effector and portion ofthe interchangeable surgical tool assembly of FIG. 13, with the anviland closure member thereof in an “over-closed” position;

FIG. 15 is a cross-sectional view of the end effector and closure memberof FIG. 14 taken along line 15-15 of FIG. 14;

FIG. 16 is a perspective view of a portion of another end effector andinterchangeable surgical shaft assembly, with an anvil thereof in anopen position;

FIG. 17 is a side elevational view of the end effector and portion ofinterchangeable surgical shaft assembly of FIG. 16, with the anvil and aclosure member thereof in a fully open position;

FIG. 18 is a cross-sectional view of the end effector and closure memberof FIG. 17, taken along line 18-18 in FIG. 17;

FIG. 19 is a side elevational view of the end effector and portion ofinterchangeable surgical shaft assembly of FIG. 17, with the anvil andclosure member thereof in a closed position;

FIG. 20 is a cross-sectional view of the end effector and closure memberof FIG. 19, taken along line 20-20 in FIG. 19;

FIG. 21 is a side elevational view of the end effector and portion ofinterchangeable surgical shaft assembly of FIG. 19, with the anvil andclosure member thereof in an over-closed position;

FIG. 22 is a cross-sectional view of the end effector and closure memberof FIG. 21, taken along line 22-22 in FIG. 21;

FIG. 23 is an end view of another distal closure member embodiment;

FIG. 24 is a side elevational view of another end effector and portionof another interchangeable surgical shaft assembly, with an anvil and aclosure member thereof in an open position;

FIG. 25 is a cross-sectional view of the end effector and closure memberof FIG. 24, taken along line 25-25 in FIG. 24;

FIG. 26 is a side elevational view of the end effector andinterchangeable surgical shaft assembly of FIG. 24, with the anvil andclosure member thereof in a closed position;

FIG. 27 is a cross-sectional view of the end effector and closure memberof FIG. 26, taken along line 27-27 in FIG. 26;

FIG. 28 is a side elevational view of the end effector andinterchangeable surgical shaft assembly of FIG. 24, with the anvil andclosure member thereof in an over-closed position;

FIG. 29 is a cross-sectional view of the end effector and closure memberof FIG. 28, taken along line 29-29 in FIG. 28;

FIG. 30 is an end view of another closure member embodiment;

FIG. 31 is a side elevational view of another end effector and portionof another interchangeable surgical shaft assembly, with an anvil and aclosure member thereof in a closed position;

FIG. 32 is another side elevational view of the end effector of theinterchangeable surgical shaft assembly of FIG. 31, with the anvil andclosure member thereof in an “over-closed’ position;

FIG. 33 is an enlarged side elevational view of a portion of the endeffector and closure member of FIG. 31, with the anvil in the closedposition;

FIG. 34 is another enlarged side elevational view of a portion of theend effector and closure member of FIG. 32, with the anvil in theover-closed position;

FIG. 35 is a side elevational view of another end effector and portionof another interchangeable surgical shaft assembly, with an anvil and aclosure member thereof in a closed position;

FIG. 36 is an enlarged side elevational view of a portion of the endeffector and closure member of FIG. 35, with the anvil in the closedposition;

FIG. 37 is another side elevational view of the end effector of theinterchangeable surgical shaft assembly of FIG. 35, with the anvil andclosure member thereof in an over-closed position;

FIG. 38 is another enlarged side elevational view of a portion of theend effector and closure member of FIG. 37, with the anvil in theover-closed position;

FIG. 39 is a perspective view of a previous surgical staple cartridgeconfigured to form flexible lines of surgical staples;

FIG. 40 is a top view of lines of surgical staples formed in tissue bythe surgical staple cartridge of FIG. 39;

FIG. 41 is a side elevational view of a previous surgical stapleembodiment;

FIG. 42 is a side elevational view of another previous surgical stapleembodiment;

FIG. 43 is a bottom perspective view of an anvil embodiment;

FIG. 44 is an enlarged perspective view of a portion of the anvil ofFIG. 43;

FIG. 45 is an enlarged top view of a portion of a staple-formingundersurface of the anvil of FIG. 43;

FIG. 46 is a cross-sectional view of a portion of a forming pocket ofthe anvil of FIG. 43;

FIG. 47 is a bottom perspective view of another anvil embodiment;

FIG. 48 is an enlarged top view of a portion of a staple-formingundersurface of the anvil of FIG. 47;

FIG. 49 is a cross-sectional view of a portion of a forming pocket ofthe anvil of FIG. 47;

FIG. 50 is a top view of a portion of a staple-forming undersurface ofanother anvil embodiment;

FIG. 51 is a top view of a portion of a staple-forming undersurface ofanother anvil embodiment;

FIG. 52 is a top view of a portion of a staple-forming undersurface ofanother anvil embodiment;

FIG. 53 is a top view of a portion of a staple-forming undersurface ofanother anvil embodiment;

FIG. 54 is a top view of a staple-forming pocket embodiment;

FIG. 55 is a top view of another staple-forming pocket embodiment;

FIG. 56 is a top view of another staple-forming pocket embodiment;

FIG. 57 is a top view of another staple-forming pocket embodiment;

FIG. 58 is a perspective view of a portion of an a staple-formingundersurface of another anvil embodiment;

FIG. 59 is a perspective view of a portion of a staple-formingundersurface of another anvil embodiment;

FIG. 60 is a perspective view of a portion of a staple-formingundersurface of another anvil embodiment;

FIG. 61 is a cross-sectional view of a previous anvil;

FIG. 62 is a photograph taken with a scanning electron microscope of across-section through a welded joint of the previous anvil of FIG. 61;

FIG. 63 is a cross-sectional view of a portion of the previous anvil ofFIGS. 61 and 62 prior to the formation of staple-forming pocketstherein;

FIG. 64 is another cross-sectional view of the previous anvil of FIG. 63after a staple-forming pocket has been coined therein;

FIG. 65 is a photograph taken with a scanning electron microscope of across-section through the previous anvil of FIG. 61;

FIG. 66 is another photograph taken with a scanning electron microscopeof a cross-section of a portion of the previous anvil of FIG. 61;

FIG. 67 is another photograph taken with a scanning electron microscopeof a cross-section of a portion of the previous anvil of FIG. 61;

FIG. 68 is another photograph taken with a scanning electron microscopeof a cross-section of a portion of the previous anvil of FIG. 61;

FIG. 69 is another photograph taken with a scanning electron microscopeof a cross-section of a portion of the previous anvil of FIG. 61;

FIG. 70 is another photograph taken with a scanning electron microscopeof a portion of a staple-forming undersurface of the previous anvil ofFIG. 61;

FIG. 71 is another photograph taken with a scanning electron microscopeof a portion of a staple-forming pocket of the previous anvil of FIG.70;

FIG. 72 is another photograph taken with a scanning electron microscopeof a portion of a bottom surface of the staple-forming pocket of FIG.71;

FIG. 73 is a diagram of a method for forming a surgical stapler anvil;

FIG. 74 is a cross-sectional view of a portion of another anvil that isformed using the method of FIG. 73;

FIG. 75 is another cross-sectional view of a portion of a completedanvil that is formed using the method of FIG. 73;

FIG. 76 is a cross-sectional view of a staple-forming pocket of theanvil of FIG. 74, prior to an application of a coining action;

FIG. 77 is another cross-sectional view of the staple-forming pocket ofFIG. 76 after the application of a coining action thereto;

FIG. 78 is a diagram of another method for forming a surgical stapleranvil;

FIG. 79 is a cross-sectional view of a staple-forming pocket of anotheranvil that is formed using the method of FIG. 78 prior to an applicationof a coining action thereto;

FIG. 80 is a top view of the staple-forming pocket of FIG. 79;

FIG. 81 is another cross-sectional view of the staple-forming pocket ofFIG. 79 after an application of a coining action thereto;

FIG. 82 is a top view of the staple-forming pocket of FIG. 81;

FIG. 83 is a diagram of another method for forming a surgical stapleranvil;

FIG. 84 is a diagram of another method for forming a surgical stapleranvil;

FIG. 85 is a diagram of another method for forming a surgical stapleranvil;

FIG. 86 is a diagram of another method for forming a surgical stapleranvil;

FIG. 87 is a diagram of another method for forming a surgical stapleranvil;

FIG. 88 is a diagram of another method for forming a surgical stapleranvil;

FIG. 89 is a diagram of another method for forming a surgical stapleranvil;

FIG. 90 is a diagram of another method for forming a surgical stapleranvil;

FIG. 91 is an exploded assembly view of a portion of an anvil and anviltip arrangement;

FIG. 92 is a side elevational view of the anvil and anvil tip of FIG.91;

FIG. 93 is a top view of the anvil and anvil tip of FIGS. 90 and 91;

FIG. 94 is an exploded assembly view of a portion of another anvil andanvil tip arrangement;

FIG. 95 is a bottom perspective view of a portion of the anvil and anviltip arrangement of FIG. 94;

FIG. 96 is a perspective view of a portion of another anvil with ananvil tip arrangement shown in phantom;

FIG. 97 is another perspective view of the anvil of FIG. 96 with theanvil tip arrangement molded thereto;

FIG. 98 is an exploded assembly view of a portion of another anvil andanvil tip arrangement; and

FIG. 99 is a perspective view of the anvil of FIG. 98 with the anvil tiparrangement attached thereto.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplifications set out hereinillustrate various embodiments of the invention, in one form, and suchexemplifications are not to be construed as limiting the scope of theinvention in any manner.

DETAILED DESCRIPTION

Applicant of the present application owns the following U.S. patentapplications that were filed on Sep. 20, 2018 and which are each hereinincorporated by reference in their respective entireties:

-   U.S. patent application Ser. No. 16/105,183, entitled REINFORCED    DEFORMABLE ANVIL TIP FOR SURGICAL STAPLER ANVIL, now U.S. Pat. No.    10,912,559;-   U.S. patent application Ser. No. 16/105,150, entitled SURGICAL    STAPLER ANVILS WITH STAPLE DIRECTING PROTRUSIONS AND TISSUE    STABILITY FEATURES, now U.S. Pat. No. 11,039,834-   U.S. patent application Ser. No. 16/105,098, entitled FABRICATING    TECHNIQUES FOR SURGICAL STAPLER ANVILS, now U.S. Pat. No.    11,045,192;-   U.S. patent application Ser. No. 16/105,122, entitled SURGICAL    STAPLING DEVICES WITH IMPROVED CLOSURE MEMBERS, now U.S. Patent    Application Publication No. 2020/0054324;-   U.S. patent application Ser. No. 16/105,140, entitled SURGICAL    STAPLER ANVILS WITH TISSUE STOP FEATURES CONFIGURED TO AVOID TISSUE    PINCH, now U.S. Pat. No. 10,779,821;-   U.S. patent application Ser. No. 16/105,081, entitled METHOD FOR    OPERATING A POWERED ARTICULATABLE SURGICAL INSTRUMENT, now U.S.    Patent Application Publication No. 2020/0054320;-   U.S. patent application Ser. No. 16/105,094, entitled SURGICAL    INSTRUMENTS WITH PROGRESSIVE JAW CLOSURE ARRANGEMENTS, now U.S.    Patent Application Publication No. 2020/0054321;-   U.S. patent application Ser. No. 16/105,097, entitled POWERED    SURGICAL INSTRUMENTS WITH CLUTCHING ARRANGEMENTS TO CONVERT LINEAR    DRIVE MOTIONS TO ROTARY DRIVE MOTIONS, now U.S. Pat. No. 11,083,458;-   U.S. patent application Ser. No. 16/105,104, entitled POWERED    ARTICULATABLE SURGICAL INSTRUMENTS WITH CLUTCHING AND LOCKING    ARRANGEMENTS FOR LINKING AN ARTICULATION DRIVE SYSTEM TO A FIRING    DRIVE SYSTEM, now U.S. Pat. No. 10,842,492;-   U.S. patent application Ser. No. 16/105,119, entitled ARTICULATABLE    MOTOR POWERED SURGICAL INSTRUMENTS WITH DEDICATED ARTICULATION MOTOR    ARRANGEMENTS, now U.S. Patent Application Publication No.    2020/0054330;-   U.S. patent application Ser. No. 16/105,160, entitled SWITCHING    ARRANGEMENTS FOR MOTOR POWERED ARTICULATABLE SURGICAL INSTRUMENTS,    now U.S. Pat. No. 10,856,870; and-   U.S. Design patent application Ser. No. 29/660,252, entitled    SURGICAL STAPLER ANVILS, now U.S. Design Pat. No. D914,878.

Applicant of the present application owns the following U.S. patentapplications and U.S. patents that are each herein incorporated byreference in their respective entireties:

-   U.S. patent application Ser. No. 15/386,185, entitled SURGICAL    STAPLING INSTRUMENTS AND REPLACEABLE TOOL ASSEMBLIES THEREOF, U.S.    Patent Application Publication No. 2018-0168642;-   U.S. patent application Ser. No. 15/386,230, entitled ARTICULATABLE    SURGICAL STAPLING INSTRUMENTS, U.S. Patent Application Publication    No. 2018-0168649;-   U.S. patent application Ser. No. 15/386,221, entitled LOCKOUT    ARRANGEMENTS FOR SURGICAL END EFFECTORS, U.S. Patent Application    Publication No. 2018-01686;-   U.S. patent application Ser. No. 15/386,209, entitled SURGICAL END    EFFECTORS AND FIRING MEMBERS THEREOF, U.S. Patent Application    Publication No. 2018-0168645;-   U.S. patent application Ser. No. 15/386,198, entitled LOCKOUT    ARRANGEMENTS FOR SURGICAL END EFFECTORS AND REPLACEABLE TOOL    ASSEMBLIES, U.S. Patent Application Publication No. 2018-0168644;-   U.S. patent application Ser. No. 15/386,240, entitled SURGICAL END    EFFECTORS AND ADAPTABLE FIRING MEMBERS THEREFOR, U.S. Patent    Application Publication No. 2018-0168651.-   U.S. patent application Ser. No. 15/385,939, entitled STAPLE    CARTRIDGES AND ARRANGEMENTS OF STAPLES AND STAPLE CAVITIES THEREIN,    U.S. Patent Application Publication No. 2018-0168629;-   U.S. patent application Ser. No. 15/385,941, entitled SURGICAL TOOL    ASSEMBLIES WITH CLUTCHING ARRANGEMENTS FOR SHIFTING BETWEEN CLOSURE    SYSTEMS WITH CLOSURE STROKE REDUCTION FEATURES AND ARTICULATION AND    FIRING SYSTEMS, U.S. Patent Application Publication No.    2018-0168630;-   U.S. patent application Ser. No. 15/385,943, entitled SURGICAL    STAPLING INSTRUMENTS AND STAPLE-FORMING ANVILS, U.S. Patent    Application Publication No. 2018-0168631;-   U.S. patent application Ser. No. 15/385,950, entitled SURGICAL TOOL    ASSEMBLIES WITH CLOSURE STROKE REDUCTION FEATURES, U.S. Patent    Application Publication No. 2018-0168635;-   U.S. patent application Ser. No. 15/385,945, entitled STAPLE    CARTRIDGES AND ARRANGEMENTS OF STAPLES AND STAPLE CAVITIES THEREIN;    U.S. Patent Application Publication No. 2018-0168632;-   U.S. patent application Ser. No. 15/385,946, entitled SURGICAL    STAPLING INSTRUMENTS AND STAPLE-FORMING ANVILS, U.S. Patent    Application Publication No. 2018-0168633;-   U.S. patent application Ser. No. 15/385,951, entitled SURGICAL    INSTRUMENTS WITH JAW OPENING FEATURES FOR INCREASING A JAW OPENING    DISTANCE, U.S. Patent Application Publication No. 2018-0168636;-   U.S. patent application Ser. No. 15/385,953, entitled METHODS OF    STAPLING TISSUE, U.S. Patent Application Publication No.    2018-0168637;-   U.S. patent application Ser. No. 15/385,954, entitled FIRING MEMBERS    WITH NON-PARALLEL JAW ENGAGEMENT FEATURES FOR SURGICAL END    EFFECTORS, U.S. Patent Application Publication No. 2018-0168638;-   U.S. patent application Ser. No. 15/385,955, entitled SURGICAL END    EFFECTORS WITH EXPANDABLE TISSUE STOP ARRANGEMENTS, U.S. Patent    Application Publication No. 2018-0168639;-   U.S. patent application Ser. No. 15/385,948, entitled SURGICAL    STAPLING INSTRUMENTS AND STAPLE-FORMING ANVILS, U.S. Patent    Application Publication No. 2018-0168584;-   U.S. patent application Ser. No. 15/385,956, entitled SURGICAL    INSTRUMENTS WITH POSITIVE JAW OPENING FEATURES, U.S. Patent    Application Publication No. 2018-0168640;-   U.S. patent application Ser. No. 15/385,958, entitled SURGICAL    INSTRUMENTS WITH LOCKOUT ARRANGEMENTS FOR PREVENTING FIRING SYSTEM    ACTUATION UNLESS AN UNSPENT STAPLE CARTRIDGE IS PRESENT, U.S. Patent    Application Publication No. 2018-0168641;-   U.S. patent application Ser. No. 15/385,947, entitled STAPLE    CARTRIDGES AND ARRANGEMENTS OF STAPLES AND STAPLE CAVITIES THEREIN,    U.S. Patent Application Publication No. 2018-0168634;-   U.S. patent application Ser. No. 15/385,896, entitled METHOD FOR    RESETTING A FUSE OF A SURGICAL INSTRUMENT SHAFT, U.S. Patent    Application Publication No. 2018-0168597;-   U.S. patent application Ser. No. 15/385,898, entitled STAPLE-FORMING    POCKET ARRANGEMENT TO ACCOMMODATE DIFFERENT TYPES OF STAPLES, U.S.    Patent Application Publication No. 2018-0168599;-   U.S. patent application Ser. No. 15/385,899, entitled SURGICAL    INSTRUMENT COMPRISING IMPROVED JAW CONTROL, U.S. Patent Application    Publication No. 2018-0168600;-   U.S. patent application Ser. No. 15/385,901, entitled STAPLE    CARTRIDGE AND STAPLE CARTRIDGE CHANNEL COMPRISING WINDOWS DEFINED    THEREIN, U.S. Patent Application Publication No. 2018-0168602;-   U.S. patent application Ser. No. 15/385,902, entitled SURGICAL    INSTRUMENT COMPRISING A CUTTING MEMBER, U.S. Patent Application    Publication No. 2018-0168603;-   U.S. patent application Ser. No. 15/385,904, entitled STAPLE FIRING    MEMBER COMPRISING A MISSING CARTRIDGE AND/OR SPENT CARTRIDGE    LOCKOUT, U.S. Patent Application Publication No. 2018-0168605;-   U.S. patent application Ser. No. 15/385,905, entitled FIRING    ASSEMBLY COMPRISING A LOCKOUT, U.S. Patent Application Publication    No. 2018-0168606;-   U.S. patent application Ser. No. 15/385,907, entitled SURGICAL    INSTRUMENT SYSTEM COMPRISING AN END EFFECTOR LOCKOUT AND A FIRING    ASSEMBLY LOCKOUT, U.S. Patent Application Publication No.    2018-0168608;-   U.S. patent application Ser. No. 15/385,908, entitled FIRING    ASSEMBLY COMPRISING A FUSE, U.S. Patent Application Publication No.    2018-0168609;-   U.S. patent application Ser. No. 15/385,909, entitled FIRING    ASSEMBLY COMPRISING A MULTIPLE FAILED-STATE FUSE, U.S. Patent    Application Publication No. 2018-0168610;

U.S. patent application Ser. No. 15/385,920, entitled STAPLE-FORMINGPOCKET ARRANGEMENTS, U.S. Patent Application Publication No.2018-0168620;

-   U.S. patent application Ser. No. 15/385,913, entitled ANVIL    ARRANGEMENTS FOR SURGICAL STAPLERS, U.S. Patent Application    Publication No. 2018-0168614;-   U.S. patent application Ser. No. 15/385,914, entitled METHOD OF    DEFORMING STAPLES FROM TWO DIFFERENT TYPES OF STAPLE CARTRIDGES WITH    THE SAME SURGICAL STAPLING INSTRUMENT, U.S. Patent Application    Publication No. 2018-0168615;-   U.S. patent application Ser. No. 15/385,893, entitled BILATERALLY    ASYMMETRIC STAPLE-FORMING POCKET PAIRS, U.S. Patent Application    Publication No. 2018-0168594;-   U.S. patent application Ser. No. 15/385,929, entitled CLOSURE    MEMBERS WITH CAM SURFACE ARRANGEMENTS FOR SURGICAL INSTRUMENTS WITH    SEPARATE AND DISTINCT CLOSURE AND FIRING SYSTEMS, U.S. Patent    Application Publication No. 2018-0168626;-   U.S. patent application Ser. No. 15/385,911, entitled SURGICAL    STAPLERS WITH INDEPENDENTLY ACTUATABLE CLOSING AND FIRING SYSTEMS,    U.S. Patent Application Publication No. 2018-0168612;-   U.S. patent application Ser. No. 15/385,927, entitled SURGICAL    STAPLING INSTRUMENTS WITH SMART STAPLE CARTRIDGES, U.S. Patent    Application Publication No. 2018-0168625;-   U.S. patent application Ser. No. 15/385,917, entitled STAPLE    CARTRIDGE COMPRISING STAPLES WITH DIFFERENT CLAMPING BREADTHS, U.S.    Patent Application Publication No. 2018-0168617;-   U.S. patent application Ser. No. 15/385,900, entitled STAPLE-FORMING    POCKET ARRANGEMENTS COMPRISING PRIMARY SIDEWALLS AND POCKET    SIDEWALLS, U.S. Patent Application Publication No. 2018-0168601;-   U.S. patent application Ser. No. 15/385,931, entitled NO-CARTRIDGE    AND SPENT CARTRIDGE LOCKOUT ARRANGEMENTS FOR SURGICAL STAPLERS, U.S.    Patent Application Publication No. 2018-0168627;-   U.S. patent application Ser. No. 15/385,915, entitled FIRING MEMBER    PIN ANGLE, U.S. Patent Application Publication No. 2018-0168616;-   U.S. patent application Ser. No. 15/385,897, entitled STAPLE-FORMING    POCKET ARRANGEMENTS COMPRISING ZONED FORMING SURFACE GROOVES, U.S.    Patent Application Publication No. 2018-0168598;-   U.S. patent application Ser. No. 15/385,922, entitled SURGICAL    INSTRUMENT WITH MULTIPLE FAILURE RESPONSE MODES, U.S. Patent    Application Publication No. 2018-0168622;-   U.S. patent application Ser. No. 15/385,924, entitled SURGICAL    INSTRUMENT WITH PRIMARY AND SAFETY PROCESSORS, U.S. Patent    Application Publication No. 2018-0168624;-   U.S. patent application Ser. No. 15/385,910, entitled ANVIL HAVING A    KNIFE SLOT WIDTH, U.S. Patent Application Publication No.    2018-0168611;-   U.S. patent application Ser. No. 15/385,903, entitled CLOSURE MEMBER    ARRANGEMENTS FOR SURGICAL INSTRUMENTS, U.S. Patent Application    Publication No. 2018-0168604;-   U.S. patent application Ser. No. 15/385,906, entitled FIRING MEMBER    PIN CONFIGURATIONS, U.S. Patent Application Publication No.    2018-0168607;-   U.S. patent application Ser. No. 15/386,188, entitled STEPPED STAPLE    CARTRIDGE WITH ASYMMETRICAL STAPLES, U.S. Patent Application    Publication No. 2018-0168585;-   U.S. patent application Ser. No. 15/386,192, entitled STEPPED STAPLE    CARTRIDGE WITH TISSUE RETENTION AND GAP SETTING FEATURES, U.S.    Patent Application Publication No. 2018-0168643;-   U.S. patent application Ser. No. 15/386,206, entitled STAPLE    CARTRIDGE WITH DEFORMABLE DRIVER RETENTION FEATURES, U.S. Patent    Application Publication No. 2018-0168586;-   U.S. patent application Ser. No. 15/386,226, entitled DURABILITY    FEATURES FOR END EFFECTORS AND FIRING ASSEMBLIES OF SURGICAL    STAPLING INSTRUMENTS, U.S. Patent Application Publication No.    2018-0168648;-   U.S. patent application Ser. No. 15/386,222, entitled SURGICAL    STAPLING INSTRUMENTS HAVING END EFFECTORS WITH POSITIVE OPENING    FEATURES, U.S. Patent Application Publication No. 2018-0168647;-   U.S. patent application Ser. No. 15/386,236, entitled CONNECTION    PORTIONS FOR DEPOSABLE LOADING UNITS FOR SURGICAL STAPLING    INSTRUMENTS, U.S. Patent Application Publication No. 2018-0168650;-   U.S. patent application Ser. No. 15/385,887, entitled METHOD FOR    ATTACHING A SHAFT ASSEMBLY TO A SURGICAL INSTRUMENT AND,    ALTERNATIVELY, TO A SURGICAL ROBOT, U.S. Patent Application    Publication No. 2018-0168589;-   U.S. patent application Ser. No. 15/385,889, entitled SHAFT ASSEMBLY    COMPRISING A MANUALLY-OPERABLE RETRACTION SYSTEM FOR USE WITH A    MOTORIZED SURGICAL INSTRUMENT SYSTEM, U.S. Patent Application    Publication No. 2018-0168590;-   U.S. patent application Ser. No. 15/385,890, entitled SHAFT ASSEMBLY    COMPRISING SEPARATELY ACTUATABLE AND RETRACTABLE SYSTEMS, U.S.    Patent Application Publication No. 2018-0168591;-   U.S. patent application Ser. No. 15/385,891, entitled SHAFT ASSEMBLY    COMPRISING A CLUTCH CONFIGURED TO ADAPT THE OUTPUT OF A ROTARY    FIRING MEMBER TO TWO DIFFERENT SYSTEMS, U.S. Patent Application    Publication No. 2018-0168592;-   U.S. patent application Ser. No. 15/385,892, entitled SURGICAL    SYSTEM COMPRISING A FIRING MEMBER ROTATABLE INTO AN ARTICULATION    STATE TO ARTICULATE AN END EFFECTOR OF THE SURGICAL SYSTEM, U.S.    Patent Application Publication No. 2018-0168593;-   U.S. patent application Ser. No. 15/385,894, entitled SHAFT ASSEMBLY    COMPRISING A LOCKOUT, U.S. Patent Application Publication No.    2018-0168595;-   U.S. patent application Ser. No. 15/385,895, entitled SHAFT ASSEMBLY    COMPRISING FIRST AND SECOND ARTICULATION LOCKOUTS, U.S. Patent    Application Publication No. 2018-0168596;-   U.S. patent application Ser. No. 15/385,916, entitled SURGICAL    STAPLING SYSTEMS, U.S. Patent Application Publication No.    2018-0168575;-   U.S. patent application Ser. No. 15/385,918, entitled SURGICAL    STAPLING SYSTEMS, U.S. Patent Application Publication No.    2018-0168618;-   U.S. patent application Ser. No. 15/385,919, entitled SURGICAL    STAPLING SYSTEMS, U.S. Patent Application Publication No.    2018-0168619;-   U.S. patent application Ser. No. 15/385,921, entitled SURGICAL    STAPLE CARTRIDGE WITH MOVABLE CAMMING MEMBER CONFIGURED TO DISENGAGE    FIRING MEMBER LOCKOUT FEATURES, U.S. Patent Application Publication    No. 2018-0168621;-   U.S. patent application Ser. No. 15/385,923, entitled SURGICAL    STAPLING SYSTEMS, U.S. Patent Application Publication No.    2018-0168623;-   U.S. patent application Ser. No. 15/385,925, entitled JAW ACTUATED    LOCK ARRANGEMENTS FOR PREVENTING ADVANCEMENT OF A FIRING MEMBER IN A    SURGICAL END EFFECTOR UNLESS AN UNFIRED CARTRIDGE IS INSTALLED IN    THE END EFFECTOR, U.S. Patent Application Publication No.    2018-0168576;-   U.S. patent application Ser. No. 15/385,926, entitled AXIALLY    MOVABLE CLOSURE SYSTEM ARRANGEMENTS FOR APPLYING CLOSURE MOTIONS TO    JAWS OF SURGICAL INSTRUMENTS, U.S. Patent Application Publication    No. 2018-0168577;-   U.S. patent application Ser. No. 15/385,928, entitled PROTECTIVE    COVER ARRANGEMENTS FOR A JOINT INTERFACE BETWEEN A MOVABLE JAW AND    ACTUATOR SHAFT OF A SURGICAL INSTRUMENT, U.S. Patent Application    Publication No. 2018-0168578;-   U.S. patent application Ser. No. 15/385,930, entitled SURGICAL END    EFFECTOR WITH TWO SEPARATE COOPERATING OPENING FEATURES FOR OPENING    AND CLOSING END EFFECTOR JAWS, U.S. Patent Application Publication    No. 2018-0168579;-   U.S. patent application Ser. No. 15/385,932, entitled ARTICULATABLE    SURGICAL END EFFECTOR WITH ASYMMETRIC SHAFT ARRANGEMENT, U.S. Patent    Application Publication No. 2018-0168628;-   U.S. patent application Ser. No. 15/385,933, entitled ARTICULATABLE    SURGICAL INSTRUMENT WITH INDEPENDENT PIVOTABLE LINKAGE DISTAL OF AN    ARTICULATION LOCK, U.S. Patent Application Publication No.    2018-0168580;-   U.S. patent application Ser. No. 15/385,934, entitled ARTICULATION    LOCK ARRANGEMENTS FOR LOCKING AN END EFFECTOR IN AN ARTICULATED    POSITION IN RESPONSE TO ACTUATION OF A JAW CLOSURE SYSTEM, U.S.    Patent Application Publication No. 2018-0168581;-   U.S. patent application Ser. No. 15/385,935, entitled LATERALLY    ACTUATABLE ARTICULATION LOCK ARRANGEMENTS FOR LOCKING AN END    EFFECTOR OF A SURGICAL INSTRUMENT IN AN ARTICULATED CONFIGURATION,    U.S. Patent Application Publication No. 2018-0168582;-   U.S. patent application Ser. No. 15/385,936, entitled ARTICULATABLE    SURGICAL INSTRUMENTS WITH ARTICULATION STROKE AMPLIFICATION    FEATURES, U.S. patent application Publication No., U.S. Patent    Application Publication No. 2018-0168583;

U.S. patent application Ser. No. 14/318,996, entitled FASTENERCARTRIDGES INCLUDING EXTENSIONS HAVING DIFFERENT CONFIGURATIONS, U.S.Patent Application Publication No. 2015-0297228;

U.S. patent application Ser. No. 14/319,006, entitled FASTENER CARTRIDGECOMPRISING FASTENER CAVITIES INCLUDING FASTENER CONTROL FEATURES, NowU.S. Pat. No. 10,010,324;

U.S. patent application Ser. No. 14/318,991, entitled SURGICAL FASTENERCARTRIDGES WITH DRIVER STABILIZING ARRANGEMENTS, now U.S. Pat. No.9,833,241;

U.S. patent application Ser. No. 14/319,004, entitled SURGICAL ENDEFFECTORS WITH FIRING ELEMENT MONITORING ARRANGEMENTS, now U.S. Pat. No.9,844,369;

U.S. patent application Ser. No. 14/319,008, entitled FASTENER CARTRIDGECOMPRISING NON-UNIFORM FASTENERS, U.S. Patent Application PublicationNo. 2015-0297232;

U.S. patent application Ser. No. 14/318,997, entitled FASTENER CARTRIDGECOMPRISING DEPLOYABLE TISSUE ENGAGING MEMBERS, U.S. Patent ApplicationPublication No. 2015-0297229;

U.S. patent application Ser. No. 14/319,002, entitled FASTENER CARTRIDGECOMPRISING TISSUE CONTROL FEATURES, now U.S. Pat. No. 9,877,721;

U.S. patent application Ser. No. 14/319,013, entitled FASTENER CARTRIDGEASSEMBLIES AND STAPLE RETAINER COVER ARRANGEMENTS, U.S. PatentApplication Publication No. 2015-0297233; and

U.S. patent application Ser. No. 14/319,016, entitled FASTENER CARTRIDGEINCLUDING A LAYER ATTACHED THERETO, U.S. Patent Application PublicationNo. 2015-0297235.

Applicant of the present application owns the following U.S. patentapplications that were filed on Jun. 24, 2016 and which are each hereinincorporated by reference in their respective entireties:

-   U.S. patent application Ser. No. 15/191,775, entitled STAPLE    CARTRIDGE COMPRISING WIRE STAPLES AND STAMPED STAPLES;-   U.S. patent application Ser. No. 15/191,807, entitled STAPLING    SYSTEM FOR USE WITH WIRE STAPLES AND STAMPED STAPLES;-   U.S. patent application Ser. No. 15/191,834, entitled STAMPED    STAPLES AND STAPLE CARTRIDGES USING THE SAME;-   U.S. patent application Ser. No. 15/191,788, entitled STAPLE    CARTRIDGE COMPRISING OVERDRIVEN STAPLES; and-   U.S. patent application Ser. No. 15/191,818, entitled STAPLE    CARTRIDGE COMPRISING OFFSET LONGITUDINAL STAPLE ROWS.

Applicant of the present application owns the following U.S. patentapplications that were filed on Jun. 24, 2016 and which are each hereinincorporated by reference in their respective entireties:

-   U.S. Design patent application Ser. No. 29/569,218, entitled    SURGICAL FASTENER;-   U.S. Design patent application Ser. No. 29/569,227, entitled    SURGICAL FASTENER;-   U.S. Design patent application Ser. No. 29/569,259, entitled    SURGICAL FASTENER CARTRIDGE; and-   U.S. Design patent application Ser. No. 29/569,264, entitled    SURGICAL FASTENER CARTRIDGE.

Applicant of the present application owns the following patentapplications that were filed on Apr. 1, 2016 and which are each hereinincorporated by reference in their respective entirety:

-   U.S. patent application Ser. No. 15/089,325, entitled METHOD FOR    OPERATING A SURGICAL STAPLING SYSTEM;-   U.S. patent application Ser. No. 15/089,321, entitled MODULAR    SURGICAL STAPLING SYSTEM COMPRISING A DISPLAY;-   U.S. patent application Ser. No. 15/089,326, entitled SURGICAL    STAPLING SYSTEM COMPRISING A DISPLAY INCLUDING A RE-ORIENTABLE    DISPLAY FIELD;-   U.S. patent application Ser. No. 15/089,263, entitled SURGICAL    INSTRUMENT HANDLE ASSEMBLY WITH RECONFIGURABLE GRIP PORTION;-   U.S. patent application Ser. No. 15/089,262, entitled ROTARY POWERED    SURGICAL INSTRUMENT WITH MANUALLY ACTUATABLE BAILOUT SYSTEM;-   U.S. patent application Ser. No. 15/089,277, entitled SURGICAL    CUTTING AND STAPLING END EFFECTOR WITH ANVIL CONCENTRIC DRIVE    MEMBER;-   U.S. patent application Ser. No. 15/089,296, entitled    INTERCHANGEABLE SURGICAL TOOL ASSEMBLY WITH A SURGICAL END EFFECTOR    THAT IS SELECTIVELY ROTATABLE ABOUT A SHAFT AXIS;-   U.S. patent application Ser. No. 15/089,258, entitled SURGICAL    STAPLING SYSTEM COMPRISING A SHIFTABLE TRANSMISSION;-   U.S. patent application Ser. No. 15/089,278, entitled SURGICAL    STAPLING SYSTEM CONFIGURED TO PROVIDE SELECTIVE CUTTING OF TISSUE;-   U.S. patent application Ser. No. 15/089,284, entitled SURGICAL    STAPLING SYSTEM COMPRISING A CONTOURABLE SHAFT;-   U.S. patent application Ser. No. 15/089,295, entitled SURGICAL    STAPLING SYSTEM COMPRISING A TISSUE COMPRESSION LOCKOUT;-   U.S. patent application Ser. No. 15/089,300, entitled SURGICAL    STAPLING SYSTEM COMPRISING AN UNCLAMPING LOCKOUT;-   U.S. patent application Ser. No. 15/089,196, entitled SURGICAL    STAPLING SYSTEM COMPRISING A JAW CLOSURE LOCKOUT;-   U.S. patent application Ser. No. 15/089,203, entitled SURGICAL    STAPLING SYSTEM COMPRISING A JAW ATTACHMENT LOCKOUT;-   U.S. patent application Ser. No. 15/089,210, entitled SURGICAL    STAPLING SYSTEM COMPRISING A SPENT CARTRIDGE LOCKOUT;-   U.S. patent application Ser. No. 15/089,324, entitled SURGICAL    INSTRUMENT COMPRISING A SHIFTING MECHANISM;-   U.S. patent application Ser. No. 15/089,335, entitled SURGICAL    STAPLING INSTRUMENT COMPRISING MULTIPLE LOCKOUTS;-   U.S. patent application Ser. No. 15/089,339, entitled SURGICAL    STAPLING INSTRUMENT;-   U.S. patent application Ser. No. 15/089,253, entitled SURGICAL    STAPLING SYSTEM CONFIGURED TO APPLY ANNULAR ROWS OF STAPLES HAVING    DIFFERENT HEIGHTS;-   U.S. patent application Ser. No. 15/089,304, entitled SURGICAL    STAPLING SYSTEM COMPRISING A GROOVED FORMING POCKET;-   U.S. patent application Ser. No. 15/089,331, entitled ANVIL    MODIFICATION MEMBERS FOR SURGICAL STAPLERS;-   U.S. patent application Ser. No. 15/089,336, entitled STAPLE    CARTRIDGES WITH ATRAUMATIC FEATURES;-   U.S. patent application Ser. No. 15/089,312, entitled CIRCULAR    STAPLING SYSTEM COMPRISING AN INCISABLE TISSUE SUPPORT;-   U.S. patent application Ser. No. 15/089,309, entitled CIRCULAR    STAPLING SYSTEM COMPRISING ROTARY FIRING SYSTEM; and-   U.S. patent application Ser. No. 15/089,349, entitled CIRCULAR    STAPLING SYSTEM COMPRISING LOAD CONTROL.

Applicant of the present application also owns the U.S. patentapplications identified below which were filed on Dec. 31, 2015 whichare each herein incorporated by reference in their respective entirety:

-   U.S. patent application Ser. No. 14/984,488, entitled MECHANISMS FOR    COMPENSATING FOR BATTERY PACK FAILURE IN POWERED SURGICAL    INSTRUMENTS;-   U.S. patent application Ser. No. 14/984,525, entitled MECHANISMS FOR    COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS;    and-   U.S. patent application Ser. No. 14/984,552, entitled SURGICAL    INSTRUMENTS WITH SEPARABLE MOTORS AND MOTOR CONTROL CIRCUITS.

Applicant of the present application also owns the U.S. patentapplications identified below which were filed on Feb. 9, 2016 which areeach herein incorporated by reference in their respective entirety:

-   U.S. patent application Ser. No. 15/019,220, entitled SURGICAL    INSTRUMENT WITH ARTICULATING AND AXIALLY TRANSLATABLE END EFFECTOR;-   U.S. patent application Ser. No. 15/019,228, entitled SURGICAL    INSTRUMENTS WITH MULTIPLE LINK ARTICULATION ARRANGEMENTS;-   U.S. patent application Ser. No. 15/019,196, entitled SURGICAL    INSTRUMENT ARTICULATION MECHANISM WITH SLOTTED SECONDARY CONSTRAINT;-   U.S. patent application Ser. No. 15/019,206, entitled SURGICAL    INSTRUMENTS WITH AN END EFFECTOR THAT IS HIGHLY ARTICULATABLE    RELATIVE TO AN ELONGATE SHAFT ASSEMBLY;-   U.S. patent application Ser. No. 15/019,215, entitled SURGICAL    INSTRUMENTS WITH NON-SYMMETRICAL ARTICULATION ARRANGEMENTS;-   U.S. patent application Ser. No. 15/019,227, entitled ARTICULATABLE    SURGICAL INSTRUMENTS WITH SINGLE ARTICULATION LINK ARRANGEMENTS;-   U.S. patent application Ser. No. 15/019,235, entitled SURGICAL    INSTRUMENTS WITH TENSIONING ARRANGEMENTS FOR CABLE DRIVEN    ARTICULATION SYSTEMS;-   U.S. patent application Ser. No. 15/019,230, entitled ARTICULATABLE    SURGICAL INSTRUMENTS WITH OFF-AXIS FIRING BEAM ARRANGEMENTS; and-   U.S. patent application Ser. No. 15/019,245, entitled SURGICAL    INSTRUMENTS WITH CLOSURE STROKE REDUCTION ARRANGEMENTS.

Applicant of the present application also owns the U.S. patentapplications identified below which were filed on Feb. 12, 2016 whichare each herein incorporated by reference in their respective entirety:

-   U.S. patent application Ser. No. 15/043,254, entitled MECHANISMS FOR    COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS;-   U.S. patent application Ser. No. 15/043,259, entitled MECHANISMS FOR    COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS;-   U.S. patent application Ser. No. 15/043,275, entitled MECHANISMS FOR    COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS;    and-   U.S. patent application Ser. No. 15/043,289, entitled MECHANISMS FOR    COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS.

Applicant of the present application owns the following patentapplications that were filed on Jun. 18, 2015 and which are each hereinincorporated by reference in their respective entirety:

-   U.S. patent application Ser. No. 14/742,925, entitled SURGICAL END    EFFECTORS WITH POSITIVE JAW OPENING ARRANGEMENTS;-   U.S. patent application Ser. No. 14/742,941, entitled SURGICAL END    EFFECTORS WITH DUAL CAM ACTUATED JAW CLOSING FEATURES;-   U.S. patent application Ser. No. 14/742,914, entitled MOVABLE FIRING    BEAM SUPPORT ARRANGEMENTS FOR ARTICULATABLE SURGICAL INSTRUMENTS;-   U.S. patent application Ser. No. 14/742,900, entitled ARTICULATABLE    SURGICAL INSTRUMENTS WITH COMPOSITE FIRING BEAM STRUCTURES WITH    CENTER FIRING SUPPORT MEMBER FOR ARTICULATION SUPPORT;-   U.S. patent application Ser. No. 14/742,885, entitled DUAL    ARTICULATION DRIVE SYSTEM ARRANGEMENTS FOR ARTICULATABLE SURGICAL    INSTRUMENTS; and-   U.S. patent application Ser. No. 14/742,876, entitled PUSH/PULL    ARTICULATION DRIVE SYSTEMS FOR ARTICULATABLE SURGICAL INSTRUMENTS.

Applicant of the present application owns the following patentapplications that were filed on Mar. 6, 2015 and which are each hereinincorporated by reference in their respective entirety:

-   U.S. patent application Ser. No. 14/640,746, entitled POWERED    SURGICAL INSTRUMENT, now U.S. Patent Application Publication No.    2016/0256184;-   U.S. patent application Ser. No. 14/640,795, entitled MULTIPLE LEVEL    THRESHOLDS TO MODIFY OPERATION OF POWERED SURGICAL INSTRUMENTS, now    U.S. Patent Application Publication No. 2016/02561185;-   U.S. patent application Ser. No. 14/640,832, entitled ADAPTIVE    TISSUE COMPRESSION TECHNIQUES TO ADJUST CLOSURE RATES FOR MULTIPLE    TISSUE TYPES, now U.S. Patent Application Publication No.    2016/0256154;-   U.S. patent application Ser. No. 14/640,935, entitled OVERLAID MULTI    SENSOR RADIO FREQUENCY (RF) ELECTRODE SYSTEM TO MEASURE TISSUE    COMPRESSION, now U.S. Patent Application Publication No.    2016/0256071;-   U.S. patent application Ser. No. 14/640,831, entitled MONITORING    SPEED CONTROL AND PRECISION INCREMENTING OF MOTOR FOR POWERED    SURGICAL INSTRUMENTS, now U.S. Patent Application Publication No.    2016/0256153;-   U.S. patent application Ser. No. 14/640,859, entitled TIME DEPENDENT    EVALUATION OF SENSOR DATA TO DETERMINE STABILITY, CREEP, AND    VISCOELASTIC ELEMENTS OF MEASURES, now U.S. Patent Application    Publication No. 2016/0256187;-   U.S. patent application Ser. No. 14/640,817, entitled INTERACTIVE    FEEDBACK SYSTEM FOR POWERED SURGICAL INSTRUMENTS, now U.S. Patent    Application Publication No. 2016/0256186;-   U.S. patent application Ser. No. 14/640,844, entitled CONTROL    TECHNIQUES AND SUB-PROCESSOR CONTAINED WITHIN MODULAR SHAFT WITH    SELECT CONTROL PROCESSING FROM HANDLE, now U.S. Patent Application    Publication No. 2016/0256155;-   U.S. patent application Ser. No. 14/640,837, entitled SMART SENSORS    WITH LOCAL SIGNAL PROCESSING, now U.S. Patent Application    Publication No. 2016/0256163;-   U.S. patent application Ser. No. 14/640,765, entitled SYSTEM FOR    DETECTING THE MIS-INSERTION OF A STAPLE CARTRIDGE INTO A SURGICAL    STAPLER, now U.S. Patent Application Publication No. 2016/0256160;-   U.S. patent application Ser. No. 14/640,799, entitled SIGNAL AND    POWER COMMUNICATION SYSTEM POSITIONED ON A ROTATABLE SHAFT, now U.S.    Patent Application Publication No. 2016/0256162; and-   U.S. patent application Ser. No. 14/640,780, entitled SURGICAL    INSTRUMENT COMPRISING A LOCKABLE BATTERY HOUSING, now U.S. Patent    Application Publication No. 2016/0256161.

Applicant of the present application owns the following patentapplications that were filed on Feb. 27, 2015, and which are each hereinincorporated by reference in their respective entirety:

-   U.S. patent application Ser. No. 14/633,576, entitled SURGICAL    INSTRUMENT SYSTEM COMPRISING AN INSPECTION STATION, now U.S. Patent    Application Publication No. 2016/0249919;-   U.S. patent application Ser. No. 14/633,546, entitled SURGICAL    APPARATUS CONFIGURED TO ASSESS WHETHER A PERFORMANCE PARAMETER OF    THE SURGICAL APPARATUS IS WITHIN AN ACCEPTABLE PERFORMANCE BAND, now    U.S. Patent Application Publication No. 2016/0249915;-   U.S. patent application Ser. No. 14/633,560, entitled SURGICAL    CHARGING SYSTEM THAT CHARGES AND/OR CONDITIONS ONE OR MORE    BATTERIES, now U.S. Patent Application Publication No. 2016/0249910;-   U.S. patent application Ser. No. 14/633,566, entitled CHARGING    SYSTEM THAT ENABLES EMERGENCY RESOLUTIONS FOR CHARGING A BATTERY,    now U.S. Patent Application Publication No. 2016/0249918;-   U.S. patent application Ser. No. 14/633,555, entitled SYSTEM FOR    MONITORING WHETHER A SURGICAL INSTRUMENT NEEDS TO BE SERVICED, now    U.S. Patent Application Publication No. 2016/0249916;-   U.S. patent application Ser. No. 14/633,542, entitled REINFORCED    BATTERY FOR A SURGICAL INSTRUMENT, now U.S. Patent Application    Publication No. 2016/0249908;-   U.S. patent application Ser. No. 14/633,548, entitled POWER ADAPTER    FOR A SURGICAL INSTRUMENT, now U.S. Patent Application Publication    No. 2016/0249909;-   U.S. patent application Ser. No. 14/633,526, entitled ADAPTABLE    SURGICAL INSTRUMENT HANDLE, now U.S. Patent Application Publication    No. 2016/0249945;-   U.S. patent application Ser. No. 14/633,541, entitled MODULAR    STAPLING ASSEMBLY, now U.S. Patent Application Publication No.    2016/0249927; and-   U.S. patent application Ser. No. 14/633,562, entitled SURGICAL    APPARATUS CONFIGURED TO TRACK AN END-OF-LIFE PARAMETER, now U.S.    Patent Application Publication No. 2016/0249917.

Applicant of the present application owns the following patentapplications that were filed on Dec. 18, 2014 and which are each hereinincorporated by reference in their respective entirety:

-   U.S. patent application Ser. No. 14/574,478, entitled SURGICAL    INSTRUMENT SYSTEMS COMPRISING AN ARTICULATABLE END EFFECTOR AND    MEANS FOR ADJUSTING THE FIRING STROKE OF A FIRING MEMBER, now U.S.    Patent Application Publication No. 2016/0174977;-   U.S. patent application Ser. No. 14/574,483, entitled SURGICAL    INSTRUMENT ASSEMBLY COMPRISING LOCKABLE SYSTEMS, now U.S. Patent    Application Publication No. 2016/0174969;-   U.S. patent application Ser. No. 14/575,139, entitled DRIVE    ARRANGEMENTS FOR ARTICULATABLE SURGICAL INSTRUMENTS, now U.S. Patent    Application Publication No. 2016/0174978;-   U.S. patent application Ser. No. 14/575,148, entitled LOCKING    ARRANGEMENTS FOR DETACHABLE SHAFT ASSEMBLIES WITH ARTICULATABLE    SURGICAL END EFFECTORS, now U.S. Patent Application Publication No.    2016/0174976;-   U.S. patent application Ser. No. 14/575,130, entitled SURGICAL    INSTRUMENT WITH AN ANVIL THAT IS SELECTIVELY MOVABLE ABOUT A    DISCRETE NON-MOVABLE AXIS RELATIVE TO A STAPLE CARTRIDGE, now U.S.    Patent Application Publication No. 2016/0174972;-   U.S. patent application Ser. No. 14/575,143, entitled SURGICAL    INSTRUMENTS WITH IMPROVED CLOSURE ARRANGEMENTS, now U.S. Patent    Application Publication No. 2016/0174983;-   U.S. patent application Ser. No. 14/575,117, entitled SURGICAL    INSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND MOVABLE FIRING BEAM    SUPPORT ARRANGEMENTS, now U.S. Patent Application Publication No.    2016/0174975;-   U.S. patent application Ser. No. 14/575,154, entitled SURGICAL    INSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND IMPROVED FIRING    BEAM SUPPORT ARRANGEMENTS, now U.S. Patent Application Publication    No. 2016/0174973;-   U.S. patent application Ser. No. 14/574,493, entitled SURGICAL    INSTRUMENT ASSEMBLY COMPRISING A FLEXIBLE ARTICULATION SYSTEM, now    U.S. Patent Application Publication No. 2016/0174970; and-   U.S. patent application Ser. No. 14/574,500, entitled SURGICAL    INSTRUMENT ASSEMBLY COMPRISING A LOCKABLE ARTICULATION SYSTEM, now    U.S. Patent Application Publication No. 2016/0174971.

Applicant of the present application owns the following patentapplications that were filed on Mar. 1, 2013 and which are each hereinincorporated by reference in their respective entirety:

-   U.S. patent application Ser. No. 13/782,295, entitled ARTICULATABLE    SURGICAL INSTRUMENTS WITH CONDUCTIVE PATHWAYS FOR SIGNAL    COMMUNICATION, now U.S. Patent Application Publication No.    2014/0246471;-   U.S. patent application Ser. No. 13/782,323, entitled ROTARY POWERED    ARTICULATION JOINTS FOR SURGICAL INSTRUMENTS, now U.S. Patent    Application Publication No. 2014/0246472;-   U.S. patent application Ser. No. 13/782,338, entitled THUMBWHEEL    SWITCH ARRANGEMENTS FOR SURGICAL INSTRUMENTS, now U.S. Patent    Application Publication No. 2014/0249557;-   U.S. patent application Ser. No. 13/782,499, entitled    ELECTROMECHANICAL SURGICAL DEVICE WITH SIGNAL RELAY ARRANGEMENT, now    U.S. Pat. No. 9,358,003;-   U.S. patent application Ser. No. 13/782,460, entitled MULTIPLE    PROCESSOR MOTOR CONTROL FOR MODULAR SURGICAL INSTRUMENTS, now U.S.    Patent Application Publication No. 2014/0246478;-   U.S. patent application Ser. No. 13/782,358, entitled JOYSTICK    SWITCH ASSEMBLIES FOR SURGICAL INSTRUMENTS, now U.S. Pat. No.    9,326,767;-   U.S. patent application Ser. No. 13/782,481, entitled SENSOR    STRAIGHTENED END EFFECTOR DURING REMOVAL THROUGH TROCAR, now U.S.    Pat. No. 9,468,438;-   U.S. patent application Ser. No. 13/782,518, entitled CONTROL    METHODS FOR SURGICAL INSTRUMENTS WITH REMOVABLE IMPLEMENT PORTIONS,    now U.S. Patent Application Publication No. 2014/0246475;-   U.S. patent application Ser. No. 13/782,375, entitled ROTARY POWERED    SURGICAL INSTRUMENTS WITH MULTIPLE DEGREES OF FREEDOM, now U.S. Pat.    No. 9,398,911; and-   U.S. patent application Ser. No. 13/782,536, entitled SURGICAL    INSTRUMENT SOFT STOP, now U.S. Pat. No. 9,307,986.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 14, 2013 and which are each hereinincorporated by reference in their respective entirety:

-   U.S. patent application Ser. No. 13/803,097, entitled ARTICULATABLE    SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, now U.S. Patent    Application Publication No. 2014/0263542;-   U.S. patent application Ser. No. 13/803,193, entitled CONTROL    ARRANGEMENTS FOR A DRIVE MEMBER OF A SURGICAL INSTRUMENT, now U.S.    Pat. No. 9,332,987;-   U.S. patent application Ser. No. 13/803,053, entitled    INTERCHANGEABLE SHAFT ASSEMBLIES FOR USE WITH A SURGICAL INSTRUMENT,    now U.S. Patent Application Publication No. 2014/0263564;-   U.S. patent application Ser. No. 13/803,086, entitled ARTICULATABLE    SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK, now U.S. Patent    Application Publication No. 2014/0263541;-   U.S. patent application Ser. No. 13/803,210, entitled SENSOR    ARRANGEMENTS FOR ABSOLUTE POSITIONING SYSTEM FOR SURGICAL    INSTRUMENTS, now U.S. Patent Application Publication No.    2014/0263538;-   U.S. patent application Ser. No. 13/803,148, entitled MULTI-FUNCTION    MOTOR FOR A SURGICAL INSTRUMENT, now U.S. Patent Application    Publication No. 2014/0263554;-   U.S. patent application Ser. No. 13/803,066, entitled DRIVE SYSTEM    LOCKOUT ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS, now U.S.    Patent Application Publication No. 2014/0263565;-   U.S. patent application Ser. No. 13/803,117, entitled ARTICULATION    CONTROL SYSTEM FOR ARTICULATABLE SURGICAL INSTRUMENTS, now U.S. Pat.    No. 9,351,726;-   U.S. patent application Ser. No. 13/803,130, entitled DRIVE TRAIN    CONTROL ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS, now U.S. Pat.    No. 9,351,727; and-   U.S. patent application Ser. No. 13/803,159, entitled METHOD AND    SYSTEM FOR OPERATING A SURGICAL INSTRUMENT, now U.S. Patent    Application Publication No. 2014/0277017.

Applicant of the present application also owns the following patentapplication that was filed on Mar. 7, 2014 and is herein incorporated byreference in its entirety:

-   U.S. patent application Ser. No. 14/200,111, entitled CONTROL    SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S. Patent Application    Publication No. 2014/0263539.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 26, 2014 and are each hereinincorporated by reference in their respective entirety:

-   U.S. patent application Ser. No. 14/226,106, entitled POWER    MANAGEMENT CONTROL SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S. Patent    Application Publication No. 2015/0272582;-   U.S. patent application Ser. No. 14/226,099, entitled STERILIZATION    VERIFICATION CIRCUIT, now U.S. Patent Application Publication No.    2015/0272581;-   U.S. patent application Ser. No. 14/226,094, entitled VERIFICATION    OF NUMBER OF BATTERY EXCHANGES/PROCEDURE COUNT, now U.S. Patent    Application Publication No. 2015/0272580;-   U.S. patent application Ser. No. 14/226,117, entitled POWER    MANAGEMENT THROUGH SLEEP OPTIONS OF SEGMENTED CIRCUIT AND WAKE UP    CONTROL, now U.S. Patent Application Publication No. 2015/0272574;-   U.S. patent application Ser. No. 14/226,075, entitled MODULAR    POWERED SURGICAL INSTRUMENT WITH DETACHABLE SHAFT ASSEMBLIES, now    U.S. Patent Application Publication No. 2015/0272579;-   U.S. patent application Ser. No. 14/226,093, entitled FEEDBACK    ALGORITHMS FOR MANUAL BAILOUT SYSTEMS FOR SURGICAL INSTRUMENTS, now    U.S. Patent Application Publication No. 2015/0272569;-   U.S. patent application Ser. No. 14/226,116, entitled SURGICAL    INSTRUMENT UTILIZING SENSOR ADAPTATION, now U.S. Patent Application    Publication No. 2015/0272571;-   U.S. patent application Ser. No. 14/226,071, entitled SURGICAL    INSTRUMENT CONTROL CIRCUIT HAVING A SAFETY PROCESSOR, now U.S.    Patent Application Publication No. 2015/0272578;-   U.S. patent application Ser. No. 14/226,097, entitled SURGICAL    INSTRUMENT COMPRISING INTERACTIVE SYSTEMS, now U.S. Patent    Application Publication No. 2015/0272570;-   U.S. patent application Ser. No. 14/226,126, entitled INTERFACE    SYSTEMS FOR USE WITH SURGICAL INSTRUMENTS, now U.S. Patent    Application Publication No. 2015/0272572;-   U.S. patent application Ser. No. 14/226,133, entitled MODULAR    SURGICAL INSTRUMENT SYSTEM, now U.S. Patent Application Publication    No. 2015/0272557;-   U.S. patent application Ser. No. 14/226,081, entitled SYSTEMS AND    METHODS FOR CONTROLLING A SEGMENTED CIRCUIT, now U.S. Patent    Application Publication No. 2015/0277471;-   U.S. patent application Ser. No. 14/226,076, entitled POWER    MANAGEMENT THROUGH SEGMENTED CIRCUIT AND VARIABLE VOLTAGE    PROTECTION, now U.S. Patent Application Publication No.    2015/0280424;-   U.S. patent application Ser. No. 14/226,111, entitled SURGICAL    STAPLING INSTRUMENT SYSTEM, now U.S. Patent Application Publication    No. 2015/0272583; and-   U.S. patent application Ser. No. 14/226,125, entitled SURGICAL    INSTRUMENT COMPRISING A ROTATABLE SHAFT, now U.S. Patent Application    Publication No. 2015/0280384.

Applicant of the present application also owns the following patentapplications that were filed on Sep. 5, 2014 and which are each hereinincorporated by reference in their respective entirety:

-   U.S. patent application Ser. No. 14/479,103, entitled CIRCUITRY AND    SENSORS FOR POWERED MEDICAL DEVICE, now U.S. Patent Application    Publication No. 2016/0066912;-   U.S. patent application Ser. No. 14/479,119, entitled ADJUNCT WITH    INTEGRATED SENSORS TO QUANTIFY TISSUE COMPRESSION, now U.S. Patent    Application Publication No. 2016/0066914;-   U.S. patent application Ser. No. 14/478,908, entitled MONITORING    DEVICE DEGRADATION BASED ON COMPONENT EVALUATION, now U.S. Patent    Application Publication No. 2016/0066910;-   U.S. patent application Ser. No. 14/478,895, entitled MULTIPLE    SENSORS WITH ONE SENSOR AFFECTING A SECOND SENSOR'S OUTPUT OR    INTERPRETATION, now U.S. Patent Application Publication No.    2016/0066909;-   U.S. patent application Ser. No. 14/479,110, entitled POLARITY OF    HALL MAGNET TO DETECT MISLOADED CARTRIDGE, now U.S. Patent    Application Publication No. 2016/0066915;-   U.S. patent application Ser. No. 14/479,098, entitled SMART    CARTRIDGE WAKE UP OPERATION AND DATA RETENTION, now U.S. Patent    Application Publication No. 2016/0066911;-   U.S. patent application Ser. No. 14/479,115, entitled MULTIPLE MOTOR    CONTROL FOR POWERED MEDICAL DEVICE, now U.S. Patent Application    Publication No. 2016/0066916; and-   U.S. patent application Ser. No. 14/479,108, entitled LOCAL DISPLAY    OF TISSUE PARAMETER STABILIZATION, now U.S. Patent Application    Publication No. 2016/0066913.

Applicant of the present application also owns the following patentapplications that were filed on Apr. 9, 2014 and which are each hereinincorporated by reference in their respective entirety:

-   U.S. patent application Ser. No. 14/248,590, entitled MOTOR DRIVEN    SURGICAL INSTRUMENTS WITH LOCKABLE DUAL DRIVE SHAFTS, now U.S.    Patent Application Publication No. 2014/0305987;-   U.S. patent application Ser. No. 14/248,581, entitled SURGICAL    INSTRUMENT COMPRISING A CLOSING DRIVE AND A FIRING DRIVE OPERATED    FROM THE SAME ROTATABLE OUTPUT, now U.S. Patent Application    Publication No. 2014/0305989;-   U.S. patent application Ser. No. 14/248,595, entitled SURGICAL    INSTRUMENT SHAFT INCLUDING SWITCHES FOR CONTROLLING THE OPERATION OF    THE SURGICAL INSTRUMENT, now U.S. Patent Application Publication No.    2014/0305988;-   U.S. patent application Ser. No. 14/248,588, entitled POWERED LINEAR    SURGICAL STAPLER, now U.S. Patent Application Publication No.    2014/0309666;-   U.S. patent application Ser. No. 14/248,591, entitled TRANSMISSION    ARRANGEMENT FOR A SURGICAL INSTRUMENT, now U.S. Patent Application    Publication No. 2014/0305991;-   U.S. patent application Ser. No. 14/248,584, entitled MODULAR MOTOR    DRIVEN SURGICAL INSTRUMENTS WITH ALIGNMENT FEATURES FOR ALIGNING    ROTARY DRIVE SHAFTS WITH SURGICAL END EFFECTOR SHAFTS, now U.S.    Patent Application Publication No. 2014/0305994;-   U.S. patent application Ser. No. 14/248,587, entitled POWERED    SURGICAL STAPLER, now U.S. Patent Application Publication No.    2014/0309665;-   U.S. patent application Ser. No. 14/248,586, entitled DRIVE SYSTEM    DECOUPLING ARRANGEMENT FOR A SURGICAL INSTRUMENT, now U.S. Patent    Application Publication No. 2014/0305990; and-   U.S. patent application Ser. No. 14/248,607, entitled MODULAR MOTOR    DRIVEN SURGICAL INSTRUMENTS WITH STATUS INDICATION ARRANGEMENTS, now    U.S. Patent Application Publication No. 2014/0305992.

Applicant of the present application also owns the following patentapplications that were filed on Apr. 16, 2013 and which are each hereinincorporated by reference in their respective entirety:

-   U.S. Provisional Patent Application Ser. No. 61/812,365, entitled    SURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED BY A SINGLE    MOTOR;-   U.S. Provisional Patent Application Ser. No. 61/812,376, entitled    LINEAR CUTTER WITH POWER;-   U.S. Provisional Patent Application Ser. No. 61/812,382, entitled    LINEAR CUTTER WITH MOTOR AND PISTOL GRIP;-   U.S. Provisional Patent Application Ser. No. 61/812,385, entitled    SURGICAL INSTRUMENT HANDLE WITH MULTIPLE ACTUATION MOTORS AND MOTOR    CONTROL; and-   U.S. Provisional Patent Application Ser. No. 61/812,372, entitled    SURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED BY A SINGLE    MOTOR.

Numerous specific details are set forth to provide a thoroughunderstanding of the overall structure, function, manufacture, and useof the embodiments as described in the specification and illustrated inthe accompanying drawings. Well-known operations, components, andelements have not been described in detail so as not to obscure theembodiments described in the specification. The reader will understandthat the embodiments described and illustrated herein are non-limitingexamples, and thus it can be appreciated that the specific structuraland functional details disclosed herein may be representative andillustrative. Variations and changes thereto may be made withoutdeparting from the scope of the claims.

The terms “comprise” (and any form of comprise, such as “comprises” and“comprising”), “have” (and any form of have, such as “has” and“having”), “include” (and any form of include, such as “includes” and“including”) and “contain” (and any form of contain, such as “contains”and “containing”) are open-ended linking verbs. As a result, a surgicalsystem, device, or apparatus that “comprises,” “has,” “includes” or“contains” one or more elements possesses those one or more elements,but is not limited to possessing only those one or more elements.Likewise, an element of a system, device, or apparatus that “comprises,”“has,” “includes” or “contains” one or more features possesses those oneor more features, but is not limited to possessing only those one ormore features.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” refers to the portion closest to the clinician andthe term “distal” refers to the portion located away from the clinician.It will be further appreciated that, for convenience and clarity,spatial terms such as “vertical”, “horizontal”, “up”, and “down” may beused herein with respect to the drawings. However, surgical instrumentsare used in many orientations and positions, and these terms are notintended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, thereader will readily appreciate that the various methods and devicesdisclosed herein can be used in numerous surgical procedures andapplications including, for example, in connection with open surgicalprocedures. As the present Detailed Description proceeds, the readerwill further appreciate that the various instruments disclosed hereincan be inserted into a body in any way, such as through a naturalorifice, through an incision or puncture hole formed in tissue, etc. Theworking portions or end effector portions of the instruments can beinserted directly into a patient's body or can be inserted through anaccess device that has a working channel through which the end effectorand elongate shaft of a surgical instrument can be advanced.

A surgical stapling system can comprise a shaft and an end effectorextending from the shaft. The end effector comprises a first jaw and asecond jaw. The first jaw comprises a staple cartridge. The staplecartridge is insertable into and removable from the first jaw; however,other embodiments are envisioned in which a staple cartridge is notremovable from, or at least readily replaceable from, the first jaw. Thesecond jaw comprises an anvil configured to deform staples ejected fromthe staple cartridge. The second jaw is pivotable relative to the firstjaw about a closure axis; however, other embodiments are envisioned inwhich the first jaw is pivotable relative to the second jaw. Thesurgical stapling system further comprises an articulation jointconfigured to permit the end effector to be rotated, or articulated,relative to the shaft. The end effector is rotatable about anarticulation axis extending through the articulation joint. Otherembodiments are envisioned which do not include an articulation joint.

The staple cartridge comprises a cartridge body. The cartridge bodyincludes a proximal end, a distal end, and a deck extending between theproximal end and the distal end. In use, the staple cartridge ispositioned on a first side of the tissue to be stapled and the anvil ispositioned on a second side of the tissue. The anvil is moved toward thestaple cartridge to compress and clamp the tissue against the deck.Thereafter, staples removably stored in the cartridge body can bedeployed into the tissue. The cartridge body includes staple cavitiesdefined therein wherein staples are removably stored in the staplecavities. The staple cavities are arranged in six longitudinal rows.Three rows of staple cavities are positioned on a first side of alongitudinal slot and three rows of staple cavities are positioned on asecond side of the longitudinal slot. Other arrangements of staplecavities and staples may be possible.

The staples are supported by staple drivers in the cartridge body. Thedrivers are movable between a first, or unfired position, and a second,or fired, position to eject the staples from the staple cavities. Thedrivers are retained in the cartridge body by a retainer which extendsaround the bottom of the cartridge body and includes resilient membersconfigured to grip the cartridge body and hold the retainer to thecartridge body. The drivers are movable between their unfired positionsand their fired positions by a sled. The sled is movable between aproximal position adjacent the proximal end and a distal positionadjacent the distal end. The sled comprises a plurality of rampedsurfaces configured to slide under the drivers and lift the drivers, andthe staples supported thereon, toward the anvil.

Further to the above, the sled is moved distally by a firing member. Thefiring member is configured to contact the sled and push the sled towardthe distal end. The longitudinal slot defined in the cartridge body isconfigured to receive the firing member. The anvil also includes a slotconfigured to receive the firing member. The firing member furthercomprises a first cam which engages the first jaw and a second cam whichengages the second jaw. As the firing member is advanced distally, thefirst cam and the second cam can control the distance, or tissue gap,between the deck of the staple cartridge and the anvil. The firingmember also comprises a knife configured to incise the tissue capturedintermediate the staple cartridge and the anvil. It is desirable for theknife to be positioned at least partially proximal to the rampedsurfaces such that the staples are ejected ahead of the knife.

FIGS. 1 and 3 depict a motor-driven surgical cutting and fasteninginstrument 1010 that may or may not be reused. In the illustratedembodiment, the instrument 1010 includes a previous housing 1012 thatcomprises a handle 1014 that is configured to be grasped, manipulatedand actuated by the clinician. The housing 1012 is configured foroperable attachment to an interchangeable shaft assembly 1200 that has asurgical end effector 1300 operably coupled thereto that is configuredto perform one or more surgical tasks or procedures. As the presentDetailed Description proceeds, it will be understood that the variousforms of interchangeable shaft assemblies disclosed herein may also beeffectively employed in connection with robotically-controlled surgicalsystems. Thus, the term “housing” may also encompass a housing orsimilar portion of a robotic system that houses or otherwise operablysupports at least one drive system that is configured to generate andapply at least one control motion which could be used to actuate theinterchangeable shaft assemblies disclosed herein and their respectiveequivalents. In addition, various components may be “housed” orcontained in the housing or various components may be “associated with”a housing. In such instances, the components may not be contained withthe housing or supported directly by the housing. The term “frame” mayrefer to a portion of a handheld surgical instrument. The term “frame”may also represent a portion of a robotically controlled surgicalinstrument and/or a portion of the robotic system that may be used tooperably control a surgical instrument. For example, the interchangeableshaft assemblies disclosed herein may be employed with various roboticsystems, instruments, components and methods disclosed in U.S. Pat. No.9,072,535, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLEDEPLOYMENT ARRANGEMENTS, that is incorporated by reference herein in itsentirety.

The previous housing 1012 depicted in FIG. 1 is shown in connection withan interchangeable shaft assembly 1200 (FIGS. 2, 4 and 5) that includesan end effector 1300 that comprises a surgical cutting and fasteningdevice that is configured to operably support a surgical staplecartridge 4000 therein. The housing 1012 may be configured for use inconnection with interchangeable shaft assemblies that include endeffectors that are adapted to support different sizes and types ofstaple cartridges, have different shaft lengths, sizes, and types, etc.In addition, the housing 1012 may also be effectively employed with avariety of other interchangeable shaft assemblies including thoseassemblies that are configured to apply other motions and forms ofenergy such as, for example, radio frequency (RF) energy, ultrasonicenergy and/or motion to end effector arrangements adapted for use inconnection with various surgical applications and procedures.Furthermore, the end effectors, shaft assemblies, handles, surgicalinstruments, and/or surgical instrument systems can utilize any suitablefastener, or fasteners, to fasten tissue. For instance, a fastenercartridge comprising a plurality of fasteners removably stored thereincan be removably inserted into and/or attached to the end effector of ashaft assembly.

FIG. 1 illustrates the surgical instrument 1010 that includes aninterchangeable shaft assembly 1200 operably coupled to the housing1012. FIG. 2 illustrates the interchangeable shaft assembly 1200detached from the housing 1012 or handle 1014. As can be seen in FIG. 3,the handle 1014 may comprise a pair of interconnectable handle housingsegments 1016 and 1018 that may be interconnected by screws, snapfeatures, adhesive, etc. In the illustrated arrangement, the handlehousing segments 1016, 1018 cooperate to form a pistol grip portion 1019that can be gripped and manipulated by the clinician. As will bediscussed in further detail below, the handle 1014 operably supports aplurality of drive systems therein that are configured to generate andapply various control motions to corresponding portions of theinterchangeable shaft assembly that is operably attached thereto.

Referring now to FIG. 3, the handle 1014 may further include a frame1020 that operably supports a plurality of drive systems. For example,the frame 1020 can operably support a “first” or closure drive system,generally designated as 1030, which may be employed to apply closing andopening motions to the interchangeable shaft assembly 1200 that isoperably attached or coupled thereto. In at least one form, the closuredrive system 1030 may include an actuator in the form of a closuretrigger 1032 that is pivotally supported by the frame 1020. Morespecifically, as illustrated in FIG. 3, the closure trigger 1032 ispivotally coupled to the housing 1014 by a pin 1033. Such arrangementenables the closure trigger 1032 to be manipulated by a clinician suchthat when the clinician grips the pistol grip portion 1019 of the handle1014, the closure trigger 1032 may be easily pivoted from a starting or“unactuated” position to an “actuated” position and more particularly toa fully compressed or fully actuated position. The closure trigger 1032may be biased into the unactuated position by spring or other biasingarrangement (not shown). In various forms, the closure drive system 1030further includes a closure linkage assembly 1034 that is pivotallycoupled to the closure trigger 1032. As can be seen in FIG. 3, theclosure linkage assembly 1034 may include a first closure link 1036 anda second closure link 1038 that are pivotally coupled to the closuretrigger 1032 by a pin 1035. The second closure link 1038 may also bereferred to herein as an “attachment member” and include a transverseattachment pin 1037.

Still referring to FIG. 3, it can be observed that the first closurelink 1036 may have a locking wall or end 1039 thereon that is configuredto cooperate with a closure release assembly 1060 that is pivotallycoupled to the frame 1020. In at least one form, the closure releaseassembly 1060 may comprise a release button assembly 1062 that has adistally protruding locking pawl 1064 formed thereon. The release buttonassembly 1062 may be pivoted in a counterclockwise direction by arelease spring (not shown). As the clinician depresses the closuretrigger 1032 from its unactuated position towards the pistol gripportion 1019 of the handle 1014, the first closure link 1036 pivotsupward to a point wherein the locking pawl 1064 drops into retainingengagement with the locking wall 1039 on the first closure link 1036thereby preventing the closure trigger 1032 from returning to theunactuated position. Thus, the closure release assembly 1060 serves tolock the closure trigger 1032 in the fully actuated position. When theclinician desires to unlock the closure trigger 1032 to permit it to bebiased to the unactuated position, the clinician simply pivots theclosure release button assembly 1062 such that the locking pawl 1064 ismoved out of engagement with the locking wall 1039 on the first closurelink 1036. When the locking pawl 1064 has been moved out of engagementwith the first closure link 1036, the closure trigger 1032 may pivotback to the unactuated position. Other closure trigger locking andrelease arrangements may also be employed.

An arm 1061 may extend from the closure release button 1062. A magneticelement 1063, such as a permanent magnet, for example, may be mounted tothe arm 1061. When the closure release button 1062 is rotated from itsfirst position to its second position, the magnetic element 1063 canmove toward a circuit board 1100. The circuit board 1100 can include atleast one sensor that is configured to detect the movement of themagnetic element 1063. In at least one embodiment, for example, a “HallEffect” sensor (not shown) can be mounted to the bottom surface of thecircuit board 1100. The Hall Effect sensor can be configured to detectchanges in a magnetic field surrounding the Hall Effect sensor caused bythe movement of the magnetic element 1063. The Hall Effect sensor can bein signal communication with a microcontroller, for example, which candetermine whether the closure release button 1062 is in its firstposition, which is associated with the unactuated position of theclosure trigger 1032 and the open configuration of the end effector, itssecond position, which is associated with the actuated position of theclosure trigger 1032 and the closed configuration of the end effector,and/or any position between the first position and the second position.

In at least one form, the handle 1014 and the frame 1020 may operablysupport another drive system referred to herein as a firing drive system1080 that is configured to apply firing motions to correspondingportions of the interchangeable shaft assembly attached thereto. Thefiring drive system may 1080 also be referred to herein as a “seconddrive system”. The firing drive system 1080 may employ an electric motor1082 that is located in the pistol grip portion 1019 of the handle 1014.In various forms, the motor 1082 may be a DC brushed driving motorhaving a maximum rotation of, approximately, 25,000 RPM, for example. Inother arrangements, the motor may include a brushless motor, a cordlessmotor, a synchronous motor, a stepper motor, or any other suitableelectric motor. The motor 1082 may be powered by a power source 1090that in one form may comprise a removable power pack 1092. As can beseen in FIG. 3, for example, the power pack 1092 may comprise a proximalhousing portion 1094 that is configured for attachment to a distalhousing portion 1096. The proximal housing portion 1094 and the distalhousing portion 1096 are configured to operably support a plurality ofbatteries 1098 therein. Batteries 1098 may each comprise, for example, aLithium Ion (“LI”) or other suitable battery. The distal housing portion1096 is configured for removable operable attachment to the circuitboard assembly 1100 which is also operably coupled to the motor 1082. Anumber of batteries 1098 may be connected in series may be used as thepower source for the surgical instrument 1010. In addition, the powersource 1090 may be replaceable and/or rechargeable.

As outlined above with respect to other various forms, the electricmotor 1082 can include a rotatable shaft (not shown) that operablyinterfaces with a gear reducer assembly 1084 that is mounted in meshingengagement with a with a set, or rack, of drive teeth 1122 on alongitudinally-movable drive member 1120. In use, a voltage polarityprovided by the power source 1090 can operate the electric motor 1082 ina clockwise direction wherein the voltage polarity applied to theelectric motor by the battery can be reversed in order to operate theelectric motor 1082 in a counter-clockwise direction. When the electricmotor 1082 is rotated in one direction, the drive member 1120 will beaxially driven in the distal direction “DD”. When the motor 82 is drivenin the opposite rotary direction, the drive member 1120 will be axiallydriven in a proximal direction “PD”. The handle 1014 can include aswitch which can be configured to reverse the polarity applied to theelectric motor 1082 by the power source 1090. As with the other formsdescribed herein, the handle 1014 can also include a sensor that isconfigured to detect the position of the drive member 1120 and/or thedirection in which the drive member 1120 is being moved.

Actuation of the motor 1082 can be controlled by a firing trigger 1130that is pivotally supported on the handle 1014. The firing trigger 1130may be pivoted between an unactuated position and an actuated position.The firing trigger 1130 may be biased into the unactuated position by aspring 1132 or other biasing arrangement such that when the clinicianreleases the firing trigger 1130, it may be pivoted or otherwisereturned to the unactuated position by the spring 1132 or biasingarrangement. In at least one form, the firing trigger 1130 can bepositioned “outboard” of the closure trigger 132 as was discussed above.In at least one form, a firing trigger safety button 1134 may bepivotally mounted to the closure trigger 1032 by pin 1035. The safetybutton 1134 may be positioned between the firing trigger 1130 and theclosure trigger 1032 and have a pivot arm 1136 protruding therefrom. SeeFIG. 21. When the closure trigger 1032 is in the unactuated position,the safety button 1134 is contained in the handle 1014 where theclinician cannot readily access it and move it between a safety positionpreventing actuation of the firing trigger 1130 and a firing positionwherein the firing trigger 1130 may be fired. As the clinician depressesthe closure trigger 1032, the safety button 1134 and the firing trigger1130 pivot down wherein they can then be manipulated by the clinician.

As indicated above, in at least one form, the longitudinally movabledrive member 1120 has a rack of teeth 1122 formed thereon for meshingengagement with a corresponding drive gear 1086 of the gear reducerassembly 1084. At least one form also includes a manually-actuatable“bailout” assembly 1140 that is configured to enable the clinician tomanually retract the longitudinally movable drive member 1120 should themotor 1082 become disabled. The bailout assembly 1140 may include alever or bailout handle assembly 1142 that is configured to be manuallypivoted into ratcheting engagement with teeth 1124 also provided in thedrive member 1120. Thus, the clinician can manually retract the drivemember 1120 by using the bailout handle assembly 1142 to ratchet thedrive member 1120 in the proximal direction “PD”. U.S. Pat. No.8,608,045, entitled POWERED SURGICAL CUTTING AND STAPLING APPARATUS WITHMANUALLY RETRACTABLE FIRING SYSTEM, discloses bailout arrangements andother components, arrangements and systems that may also be employedwith the various instruments disclosed herein. U.S. Pat. No. 8,608,045,is hereby incorporated by reference herein in its entirety.

Turning now to FIGS. 2 and 5, the interchangeable shaft assembly 1200includes a surgical end effector 1300 that comprises an elongate channel1310 that is configured to operably support a staple cartridge 4000therein. The end effector 1300 may further include an anvil 2000 that ispivotally supported relative to the elongate channel 1310. Theinterchangeable shaft assembly 1200 may further include an articulationjoint 3020 and an articulation lock 2140 which can be configured toreleasably hold the end effector 1300 in a desired position relative toa shaft axis SA. Examples of various features of at least one form ofthe end effector 1300, the articulation joint 3020 and articulationlocks may be found in U.S. patent application Ser. No. 13/803,086, filedMar. 14, 2013, entitled ARTICULATABLE SURGICAL INSTRUMENT COMPRISING ANARTICULATION LOCK. The entire disclosure of U.S. patent application Ser.No. 13/803,086, filed Mar. 14, 2013, entitled ARTICULATABLE SURGICALINSTRUMENT COMPRISING AN ARTICULATION LOCK is hereby incorporated byreference herein. As can be seen in FIG. 4, the interchangeable shaftassembly 1200 can further include a proximal housing or nozzle 1201comprised of nozzle portions 1202 and 1203.

The interchangeable shaft assembly 1200 can further include a closuresystem or closure member assembly 3000 which can be utilized to closeand/or open the anvil 2000 of the end effector 1300. The shaft assembly1200 can include a spine 1210 that is configured to, one, slidablysupport a firing member therein and, two, slidably support the closuremember assembly 3000 which extends around the spine 1210. As can be seenin FIG. 5, a distal end 1211 of spine 1210 terminates in an upper lugmount feature 1270 and in a lower lug mount feature 1280. The upper lugmount feature 1270 is formed with a lug slot 1272 therein that isadapted to mountingly support an upper mounting link 1274 therein.Similarly, the lower lug mount feature 1280 is formed with a lug slot1282 therein that is adapted to mountingly support a lower mounting link1284 therein. The upper mounting link 1274 includes a pivot socket 1276therein that is adapted to rotatably receive therein a pivot pin 1292that is formed on a channel cap or anvil retainer 1290 that is attachedto a proximal end portion 1312 of the elongate channel 1310. The lowermounting link 1284 includes lower pivot pin 1286 that adapted to bereceived within a pivot hole 1314 formed in the proximal end portion1312 of the elongate channel 1310. See FIG. 5. The lower pivot pin 1286is vertically aligned with the pivot socket 1276 to define anarticulation axis AA about which the surgical end effector 1300 mayarticulate relative to the shaft axis SA. See FIG. 2.

In the illustrated example, the surgical end effector 1300 isselectively articulatable about the articulation axis AA by anarticulation system 2100. In one form, the articulation system 2100includes proximal articulation driver 2102 that is pivotally coupled toan articulation link 2120. As can be most particularly seen in FIG. 5,an offset attachment lug 2114 is formed on a distal end 2112 of theproximal articulation driver 2102. A pivot hole 2116 is formed in theoffset attachment lug 2114 and is configured to pivotally receivetherein a proximal link pin 2124 formed on the proximal end 2122 of thearticulation link 3020. A distal end 2126 of the articulation link 2120includes a pivot hole 2128 that is configured to pivotally receivetherein a channel pin 1317 formed on the proximal end portion 1312 ofthe elongate channel 1310. Thus, axial movement of proximal articulationdriver 2102 will thereby apply articulation motions to the elongatechannel 1310 to thereby cause the surgical end effector 1300 toarticulate about the articulation axis AA relative to the spine assembly1210. Further details concerning the construction and operation of thearticulation system 2100 may be found in various references incorporatedby reference herein including U.S. patent application Ser. No.15/635,631, filed Jun. 28, 2017, entitled SURGICAL INSTRUMENT WITHAXIALLY MOVABLE CLOSURE MEMBER, the entire disclosure of which is herebyincorporated by reference herein. In various circumstances, the proximalarticulation driver 2102 can be held in position by an articulation lock2140 when the proximal articulation driver 2102 is not being moved inthe proximal or distal directions. Additional details regarding anexample of an articulation lock 2140 may be found in U.S. patentapplication Ser. No. 15/635,631 as well as in other referencesincorporated by reference herein.

In various circumstances, the spine 1210 can comprise a proximal end1211 which is rotatably supported in a chassis 1240. In one arrangement,for example, the proximal end 1211 of the spine 1210 has a thread 1214formed thereon for threaded attachment to a spine bearing 1216configured to be supported within the chassis 1240. See FIG. 4. Such anarrangement facilitates rotatable attachment of the spine 1210 to thechassis 1240 such that the spine 1210 may be selectively rotated about ashaft axis SA relative to the chassis 1240.

Referring primarily to FIG. 4, the interchangeable shaft assembly 1200includes a closure shuttle 1250 that is slidably supported within thechassis 1240 such that it may be axially moved relative thereto. Theclosure shuttle 1250 includes a pair of proximally-protruding hooks 1252that are configured for attachment to the attachment pin 1037 (FIGS. 2and 3) that is attached to the second closure link 1038 as will bediscussed in further detail below. In at least one example, the closuremember assembly 3000 comprises a proximal closure member segment 3010that has a proximal end 3012 that is coupled to the closure shuttle 1250for relative rotation thereto. For example, a U shaped connector 1263 isinserted into an annular slot 3014 in the proximal end 3012 of theproximal closure member segment 3010 and is retained within verticalslots 1253 in the closure shuttle 1250. Such an arrangement serves toattach the proximal closure tube segment 3010 to the closure shuttle1250 for axial travel therewith while enabling the proximal closure tubesegment 3010 to rotate relative to the closure shuttle 1250 about theshaft axis SA. A closure spring 1268 is journaled on the proximalclosure tube segment 3010 and serves to bias the proximal closure tubesegment 3010 in the proximal direction “PD” which can serve to pivot theclosure trigger 1032 into the unactuated position when the shaftassembly is operably coupled to the handle 1014.

In at least one form, the interchangeable shaft assembly 1200 mayfurther include an articulation joint 3020. Other interchangeable shaftassemblies, however, may not be capable of articulation. As can be seenin FIG. 5, for example, a distal closure member or distal closure tubesegment 3030 is coupled to the distal end of the proximal closure memberor proximal closure tube segment 3010. The articulation joint 3020includes a double pivot closure sleeve assembly 3022. According tovarious forms, the double pivot closure sleeve assembly 3022 includes anend effector closure tube 3050 having upper and lower distallyprojecting tangs 3052, 3054. An upper double pivot link 3056 includesupwardly projecting distal and proximal pivot pins that engagerespectively an upper distal pin hole in the upper proximally projectingtang 3052 and an upper proximal pin hole in an upper distally projectingtang 3032 on the distal closure tube segment 3030. A lower double pivotlink 3058 includes upwardly projecting distal and proximal pivot pinsthat engage respectively a lower distal pin hole in the lower proximallyprojecting tang 3054 and a lower proximal pin hole in the lower distallyprojecting tang 3034. See FIGS. 4 and 5. As will be discussed in furtherdetail below, the closure tube assembly 3000 is translated distally(direction “DD”) to close the anvil 2000, for example, in response tothe actuation of the closure trigger 1032. The anvil 2000 is opened byproximally translating the closure tube assembly 3000 which causes theend effector closure sleeve to interact with the anvil 2000 and pivot itto an open position.

As was also indicated above, the interchangeable shaft assembly 1200further includes a firing member 1900 that is supported for axial travelwithin the shaft spine 1210. The firing member includes an intermediatefiring shaft portion 1222 that is configured for attachment to a distalcutting portion or knife bar 1910. The intermediate firing shaft portion1222 may include a longitudinal slot 1223 in the distal end thereofwhich can be configured to receive a tab 1912 on the proximal end of thedistal knife bar 1910. The longitudinal slot 1223 and the proximal endtab 1912 can be sized and configured to permit relative movementtherebetween and can comprise a slip joint. The slip joint 1914 canpermit the intermediate firing shaft portion 1222 of the firing drive tobe moved to articulate the end effector 1300 without moving, or at leastsubstantially moving, the knife bar 1910. Once the end effector 1300 hasbeen suitably oriented, the intermediate firing shaft portion 1222 canbe advanced distally until a proximal sidewall of the longitudinal slot1223 comes into contact with the tab 1912 in order to advance the knifebar 1910 and fire the staple cartridge 4000 positioned within thechannel 1310. The knife bar 1910 includes a knife portion 1920 thatincludes a blade or tissue cutting edge 1922 and includes an upper anvilengagement tab 1924 and lower channel engagement tabs 1926. Variousfiring member configurations and operations are disclosed in variousother references incorporated herein by reference.

As can be seen in FIG. 4, the shaft assembly 1200 further includes aswitch drum 1500 that is rotatably received on the closure tube 1260.The switch drum 1500 comprises a hollow shaft segment 1502 that has ashaft boss formed thereon for receive an outwardly protruding actuationpin therein. In various circumstances, the actuation pin extends througha longitudinal slot provided in the lock sleeve to facilitate axialmovement of the lock sleeve when it is engaged with the articulationdriver. A rotary torsion spring 1420 is configured to engage the boss onthe switch drum 1500 and a portion of the nozzle housing 1203 to apply abiasing force to the switch drum 1500. The switch drum 1500 can furthercomprise at least partially circumferential openings 1506 definedtherein which can be configured to receive circumferential mountsextending from the nozzle halves 1202, 1203 and permit relativerotation, but not translation, between the switch drum 1500 and theproximal nozzle 1201. The mounts also extend through openings 3011 inthe proximal closure tube segment 3010 to be seated in recesses 1219 inthe spine shaft 1210. Rotation of the switch drum 1500 about the shaftaxis SA will ultimately result in the rotation of the actuation pin andthe lock sleeve between its engaged and disengaged positions. In onearrangement, the rotation of the switch drum 1500 may be linked to theaxial advancement of the closure tube or closure member. Thus, inessence, actuation of the closure system may operably engage anddisengage the articulation drive system with the firing drive system inthe various manners described in further detail in U.S. patentapplication Ser. No. 13/803,086 and U.S. Pat. No. 9,913,642, entitledSURGICAL INSTRUMENT COMPRISING A SENSOR SYSTEM, the entire disclosuresof each being hereby incorporated by reference herein. For example, whenthe closure tube is in its proximal-most position corresponding to a“jaws open” position, the closure tube segment 3010 will have positionedthe switch drum 1500 so as to link the articulation system with thefiring drive system. When, the closure tube has been moved to its distalposition corresponding to a “jaws closed” position, the closure tube hasrotated the switch drum 1500 to a position wherein the articulationsystem is delinked from the firing drive system.

As also illustrated in FIG. 4, the shaft assembly 1200 can comprise aslip ring assembly 1600 which can be configured to conduct electricalpower to and/or from the end effector 1300 and/or communicate signals toand/or from the end effector 1300, for example. The slip ring assembly1600 can comprise a proximal connector flange 1604 that is mounted to achassis flange 1242 that extends from the chassis 1240 and a distalconnector flange that is positioned within a slot defined in the shafthousings. The proximal connector flange 1604 can comprise a first faceand the distal connector flange can comprise a second face which ispositioned adjacent to and movable relative to the first face. Thedistal connector flange can rotate relative to the proximal connectorflange 1604 about the shaft axis SA. The proximal connector flange 1604can comprise a plurality of concentric, or at least substantiallyconcentric, conductors defined in the first face thereof. A connectorcan be mounted on the proximal side of the connector flange and may havea plurality of contacts wherein each contact corresponds to and is inelectrical contact with one of the conductors. Such an arrangementpermits relative rotation between the proximal connector flange 1604 andthe distal connector flange while maintaining electrical contacttherebetween. The proximal connector flange 1604 can include anelectrical connector 1606 which can place the conductors in signalcommunication with a shaft circuit board 1610 mounted to the shaftchassis 1240, for example. In at least one instance, a wiring harnesscomprising a plurality of conductors can extend between the electricalconnector 1606 and the shaft circuit board 1610. The electricalconnector 1606 may extend proximally through a connector opening 1243defined in the chassis mounting flange 1242. See FIG. 4. Further detailsregarding slip ring assembly 1600 may be found in U.S. patentapplication Ser. No. 13/803,086, U.S. patent application Ser. No.13/800,067, entitled STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM,filed on Mar. 13, 2013, and U.S. Pat. No. 9,345,481, entitled STAPLECARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, for example. U.S. patentapplication Ser. No. 13/803,086, U.S. patent application Ser. No.13/800,067 and U.S. Pat. No. 9,345,481 are each hereby incorporated byreference herein in their respective entireties.

As discussed above, the shaft assembly 1200 can include a proximalportion which is fixably mounted to the handle 1014 and a distal portionwhich is rotatable about a longitudinal axis. The rotatable distal shaftportion can be rotated relative to the proximal portion about the slipring assembly 1600, as discussed above. The distal connector flange ofthe slip ring assembly 1600 can be positioned within the rotatabledistal shaft portion. Moreover, further to the above, the switch drum1500 can also be positioned within the rotatable distal shaft portion.When the rotatable distal shaft portion is rotated, the distal connectorflange and the switch drum 1500 can be rotated synchronously with oneanother. In addition, the switch drum 1500 can be rotated between afirst position and a second position relative to the distal connectorflange. When the switch drum 1500 is in its first position, thearticulation drive system may be operably disengaged from the firingdrive system and, thus, the operation of the firing drive system may notarticulate the end effector 1300 of the shaft assembly 1200. When theswitch drum 1500 is in its second position, the articulation drivesystem may be operably engaged with the firing drive system and, thus,the operation of the firing drive system may articulate the end effector1300 of the shaft assembly 1200. When the switch drum 1500 is movedbetween its first position and its second position, the switch drum 1500is moved relative to distal connector flange. In various instances, theshaft assembly 1200 can comprise at least one sensor configured todetect the position of the switch drum 1500.

Referring again to FIG. 4, the chassis 1240 includes at least one, andpreferably two, tapered attachment portions 1244 formed thereon that areadapted to be received within corresponding dovetail slots 1702 formedwithin a distal attachment flange portion 1700 of the frame 1020. SeeFIG. 3. Each dovetail slot 1702 may be tapered or, stated another way,be somewhat V-shaped to seatingly receive the attachment portions 1244therein. As can be further seen in FIG. 22, a shaft attachment lug 1226is formed on the proximal end of the intermediate firing shaft 1222. Aswill be discussed in further detail below, when the interchangeableshaft assembly 1200 is coupled to the handle 1014, the shaft attachmentlug 1226 is received in a firing shaft attachment cradle 1126 formed inthe distal end 1125 of the longitudinal drive member 1120. See FIG. 3.

Various shaft assembly embodiments employ a latch system 1710 forremovably coupling the shaft assembly 1200 to the housing 1012 and morespecifically to the frame 1020. As can be seen in FIG. 4, for example,in at least one form, the latch system 1710 includes a lock member orlock yoke 1712 that is movably coupled to the chassis 1240. In theillustrated embodiment, for example, the lock yoke 1712 has a U-shapewith two spaced downwardly extending legs 1714. The legs 1714 each havea pivot lug 1715 formed thereon that are adapted to be received incorresponding holes 1245 formed in the chassis 1240. Such arrangementfacilitates pivotal attachment of the lock yoke 1712 to the chassis1240. The lock yoke 1712 may include two proximally protruding lock lugs1716 that are configured for releasable engagement with correspondinglock detents or grooves 1704 in the distal attachment flange 1700 of theframe 1020. See FIG. 3. In various forms, the lock yoke 1712 is biasedin the proximal direction by spring or biasing member (not shown).Actuation of the lock yoke 1712 may be accomplished by a latch button1722 that is slidably mounted on a latch actuator assembly 1720 that ismounted to the chassis 1240. The latch button 1722 may be biased in aproximal direction relative to the lock yoke 1712. As will be discussedin further detail below, the lock yoke 1712 may be moved to an unlockedposition by biasing the latch button the in distal direction which alsocauses the lock yoke 1712 to pivot out of retaining engagement with thedistal attachment flange 1700 of the frame 1020. When the lock yoke 1712is in “retaining engagement” with the distal attachment flange 1700 ofthe frame 1020, the lock lugs 1716 are retainingly seated within thecorresponding lock detents or grooves 1704 in the distal attachmentflange 1700.

When employing an interchangeable shaft assembly that includes an endeffector of the type described herein that is adapted to cut and fastentissue, as well as other types of end effectors, it may be desirable toprevent inadvertent detachment of the interchangeable shaft assemblyfrom the housing during actuation of the end effector. For example, inuse the clinician may actuate the closure trigger 1032 to grasp andmanipulate the target tissue into a desired position. Once the targettissue is positioned within the end effector 1300 in a desiredorientation, the clinician may then fully actuate the closure trigger1032 to close the anvil 1306 and clamp the target tissue in position forcutting and stapling. In that instance, the first drive system 1030 hasbeen fully actuated. After the target tissue has been clamped in the endeffector 1300, it may be desirable to prevent the inadvertent detachmentof the shaft assembly 1200 from the housing 1012. One form of the latchsystem 1710 is configured to prevent such inadvertent detachment.

As can be most particularly seen in FIG. 4, the lock yoke 1712 includesat least one and preferably two lock hooks 1718 that are adapted tocontact corresponding lock lug portions 1256 that are formed on theclosure shuttle 1250. When the closure shuttle 1250 is in an unactuatedposition (i.e., the first drive system 1030 is unactuated and the anvil1306 is open), the lock yoke 1712 may be pivoted in a distal directionto unlock the interchangeable shaft assembly 1200 from the housing 1012.When in that position, the lock hooks 1718 do not contact the lock lugportions 1256 on the closure shuttle 1250. However, when the closureshuttle 1250 is moved to an actuated position (i.e., the first drivesystem 1030 is actuated and the anvil 1306 is in the closed position),the lock yoke 1712 is prevented from being pivoted to an unlockedposition. Stated another way, if the clinician were to attempt to pivotthe lock yoke 1712 to an unlocked position or, for example, the lockyoke 1712 was in advertently bumped or contacted in a manner that mightotherwise cause it to pivot distally, the lock hooks 1718 on the lockyoke 1712 will contact the lock lugs 1256 on the closure shuttle 1250and prevent movement of the lock yoke 1712 to an unlocked position.

Attachment of the interchangeable shaft assembly 1200 to the handle 1014will now be described. To commence the coupling process, the clinicianmay position the chassis 1240 of the interchangeable shaft assembly 1200above or adjacent to the distal attachment flange 1700 of the frame 1020such that the tapered attachment portions 1244 formed on the chassis1240 are aligned with the dovetail slots 1702 in the frame 1020. Theclinician may then move the shaft assembly 1200 along an installationaxis that is perpendicular to the shaft axis SA to seat the attachmentportions 1244 in “operable engagement” with the corresponding dovetailreceiving slots 1702. In doing so, the shaft attachment lug 1226 on theintermediate firing shaft 1222 will also be seated in the cradle 1126 inthe longitudinally movable drive member 1120 and the portions of pin1037 on the second closure link 1038 will be seated in the correspondinghooks 1252 in the closure yoke 1250. As used herein, the term “operableengagement” in the context of two components means that the twocomponents are sufficiently engaged with each other so that uponapplication of an actuation motion thereto, the components may carry outtheir intended action, function and/or procedure.

At least five systems of the interchangeable shaft assembly 1200 can beoperably coupled with at least five corresponding systems of the handle1014. A first system can comprise a frame system which couples and/oraligns the frame or spine of the shaft assembly 1200 with the frame 1020of the handle 1014. Another system can comprise a closure drive system1030 which can operably connect the closure trigger 1032 of the handle1014 and the closure tube 1260 and the anvil 2000 of the shaft assembly1200. As outlined above, the closure tube attachment yoke 1250 of theshaft assembly 1200 can be engaged with the pin 1037 on the secondclosure link 1038. Another system can comprise the firing drive system1080 which can operably connect the firing trigger 1130 of the handle1014 with the intermediate firing shaft 1222 of the shaft assembly 1200.As outlined above, the shaft attachment lug 1226 can be operablyconnected with the cradle 1126 of the longitudinal drive member 1120.Another system can comprise an electrical system which can signal to acontroller in the handle 1014, such as microcontroller, for example,that a shaft assembly, such as shaft assembly 1200, for example, hasbeen operably engaged with the handle 1014 and/or, two, conduct powerand/or communication signals between the shaft assembly 1200 and thehandle 1014. For instance, the shaft assembly 1200 can include anelectrical connector 1810 that is operably mounted to the shaft circuitboard 1610. The electrical connector 1810 is configured for matingengagement with a corresponding electrical connector 1800 on the handlecontrol board 1100. Further details regaining the circuitry and controlsystems may be found in U.S. patent application Ser. No. 13/803,086, andU.S. patent application Ser. No. 14/226,142, the entire disclosures ofeach which were previously incorporated by reference herein. The fifthsystem may consist of the latching system for releasably locking theshaft assembly 1200 to the handle 1014.

Referring now to FIGS. 5-7, the anvil 2000 in the illustrated exampleincludes an anvil body 2002 that terminates in anvil mounting portion2010. The anvil mounting portion 2010 is movably or pivotably supportedon the elongate channel 1310 for selective pivotal travel relativethereto about a fixed anvil pivot axis PA that is transverse to theshaft axis SA. In the illustrated arrangement, a pivot member or anviltrunnion 2012 extends laterally out of each lateral side of the anvilmounting portion 2010 to be received in a corresponding trunnion cradle1316 formed in the upstanding walls 1315 of the proximal end portion1312 of the elongate channel 1310. The anvil trunnions 2012 arepivotally retained in their corresponding trunnion cradle 1316 by thechannel cap or anvil retainer 1290. The channel cap or anvil retainer1290 includes a pair of attachment lugs that are configured to beretainingly received within corresponding lug grooves or notches formedin the upstanding walls 1315 of the proximal end portion 1312 of theelongate channel 1310.

Referring to FIGS. 7, 8 and 9, in at least one arrangement, the distalclosure member or end effector closure tube 3050 employs two axiallyoffset, proximal and distal positive jaw opening features 3060 and 3062.In FIG. 7, the proximal positive jaw opening feature 2060 is located onthe right side (as viewed by a user of the tool assembly) of the shaftaxis SA. The positive jaw opening features 3060, 3062 are configured tointeract with corresponding relieved areas 3064, 3066 and steppedportions formed on the anvil mounting portion 2010 as described infurther detail in U.S. patent application Ser. No. 15/635,631, filedJun. 28, 2017, entitled SURGICAL INSTRUMENT WITH AXIALLY MOVABLE CLOSUREMEMBER, the entire disclosure which has been herein incorporated byreference. Other jaw opening arrangements may be employed.

FIGS. 6 and 7 illustrate one form of an anvil 2000 that includes anelongate anvil body portion 2002 that terminates in an mounting portion2010 that is configured to interact with the end effector closure sleeve3050 to minimize the amount of resultant forces experienced by the endeffector closure tube 3050 as the anvil 2000 is moved from a fully openposition to a closed position and ultimately an over-closed position.The anvil body portion 2002 includes a staple-forming undersurface 2004that has a series of anvil forming pockets (not shown) formed therein.An elongate slot 2006 extends through the body portion 2002 and themounting portion 2010 to facilitate passage of the knife portion or“firing member” 1920 therethrough. In addition, an anvil cover 2030 isattached to the anvil body 2002 to cover the slot 2006. In variouscircumstances, the anvil mounting portion 2010 comprises anvil camsurface 2020 formed thereon. The anvil cam surface 2020 is bisected orotherwise split by the elongate slot 2006. As can be seen in FIGS. 6 and7, a proximal end portion 2032 of the anvil cover 2030 is oriented at anangle that corresponds to the angle/orientation of the anvil camsurfaces 2020. FIGS. 10 and 11 illustrate the anvil 2000 in a fully openposition. As can be seen in FIG. 10, the distal or end effector closuretube 3050 is in its proximal most position when the “second jaw” oranvil 2000 is in its fully open position. When in that position, a camsurface 3072 formed on the distal end 3070 of the end effector closuretube 3050 is not applying any closure forces to the cam closure surfaces2020. As the end effector closure tube 3050 is moved distally, the camsurface 3072 on the end effector closure tube 3050 contacts the camclosure surfaces 2020 on the anvil mounting portion 2010 and acorresponding closure surface 2034 on the proximal end portion 2032 ofthe anvil cover 2030 to pivot the anvil 2000 into a “closed” position.FIGS. 12 and 13 illustrate the positions of the end effector closuretube 3050 and the anvil 2000 when the anvil 2000 is in the closedposition.

As the end effector closure tube 3050 continues to be advanced distallyto apply additional closure motions to the anvil to ultimately move theanvil to an “over-closed” position, the end effector closure tube mayexperience significant stress which may, overtime, cause the endeffector closure tube to become elongated vertically (when viewed froman end) or, stated another way, become somewhat oval in shape which mayultimately lead to failure or otherwise detrimentally effect the abilityto attain a fully closed position. It is axiomatic that when athin-walled tube or cylinder is subjected to internal pressure, a “hoop”and longitudinal stress are produced in the wall of the tube. This hoopstress is acting circumferential and perpendicular to the axis andradius of the cylinder wall. Such hoop stress may be calculated as:

σ_(h) =pd/(2t), where:

σ_(h)=hoop stress (MPa,psi)

-   -   p=internal pressure in the tube or cylinder (MPa, psi)    -   d=internal diameter of tube or cylinder (mm, in)    -   t=tube or cylinder wall thickness (mm, in)        End effector closure tubes with various tube wall configurations        have been developed. Examples of such tube configurations are        disclosed in U.S. patent application Ser. No. 15/385,903, filed        Dec. 21, 2016, entitled CLOSURE MEMBER ARRANGEMENTS FOR SURGICAL        INSTRUMENTS, the entire disclosure of which is hereby        incorporated by reference herein.

FIGS. 8 and 9 illustrate one form of an end effector closure tube 3050.The closure tube 3050 comprises an external surface 3074 and an internalwall surface 3076. In at least one form, the closure tube 3050 comprisesa constant internal diameter ID and a constant external diameter OD todefine a wall thickness CT that is uniform or constant throughout alength of the closure tube 3050 or at least the portion of the closuretube that is configured to interface with the end effector jaws such asthe anvil 2000 and the elongate channel 1310.

Returning now to FIG. 12, in at least one arrangement, when the anvil2000 is in the “closed position”, a clearance distance “CD” may beobserved between the staple-forming underside 2004 of the anvil body2002 and the cartridge deck surface of a cartridge that is supportedwithin the elongate channel 1310 when no tissue is clamped between theanvil 2000 and the cartridge. FIG. 13 is a cross-sectional view takenalong line 13-13 in FIG. 12 across the closure cam surfaces 2020 as wellas through a distal end portion of the end effector closure tube 3050 aswell as the anvil mounting portion 2020 and the proximal end portion ofthe elongate channel 1310. As can be seen in that Figure, variousclosure forces CF are applied to the anvil 2000 and elongate channel1310 by the end effector closure tube 3050. For example, closure forcesCF are applied onto the closure cam surfaces 2020 and the proximal endportion 2032 of the anvil cap 2030 as well as onto the elongate channel1310.

In the example illustrated in FIGS. 6-15, the anvil mounting portion2020 is formed to establish a plurality of discrete load transferlocations that are configured to be contacted by the inner surface 3076of the end effector closure tube 3050 when the end effector closure tube3050 is in the position corresponding to the closed position of theanvil 2000. In at least one arrangement, at least two discrete loadtransfer locations are located on each side of a vertical plane VP thatbisects the anvil 2000 when the anvil 2000 is in the closed position.For example, in FIG. 13, a first right load transfer location or edge2070R, a second right load transfer location or edge 2072R, a thirdright load transfer location or edge 2074R and a fourth right loadtransfer location or edge 2076R are formed on a right side of thevertical plane VP. Similarly, a first left load transfer location oredge 2070L, a second left load transfer location or edge 2072L, a thirdleft load transfer location or edge 2074L and a fourth left loadtransfer location or edge 2076L are formed on a left side of thevertical plane VP. As used in this context, the term “at least twodiscrete load transfer locations” means that the load transfer locationsare formed relative to each other so that a space or clearance is formedbetween the portion of the anvil mounting portion 2010 extending betweenthe load transfer locations and the inner surface 3076 of the endeffector closure tube 3050.

For example, a first amount of clearance CR₁ is formed between the innersurface 3076 of the end effector closure tube 3050 extending between thefirst right load transfer location 2070R and the second right loadtransfer location 2072R. A second amount of clearance CR₂ is formedbetween the inner surface of the end effector closure tube 3050extending between the third right load transfer location 2072R and thethird right load transfer location 2074R. A third amount of clearanceCR₃ is formed between the third right load transfer location 2074R andthe fourth right load transfer location 2076R. A first amount ofclearance CL₁ is formed between the inner surface of the end effectorclosure tube extending between the first left load transfer location2070L and the second left load transfer location 2072L. A second amountof clearance CL₂ is formed between the inner surface 3076 of the endeffector closure tube extending between the second left load transferlocation 2072L and the third left load transfer location 2074L. A thirdamount of clearance CL₃ is formed between the third left load transferlocation 2074L and the fourth left load transfer location 2076L. In atleast one arrangement, the closure forces CF applied to the closure camsurfaces 2020, as well as the proximal portion 2032 of the anvil cap2030 may be evenly distributed between the first right load transferlocation 2070R and the first left load transfer location 2070L.Likewise, the closure forces CF applied to the elongate channel 1310 maybe evenly distributed between the fourth right load transfer location2076R and the fourth left load transfer location 2076L, for example.

In at least one arrangement, at least two right load transfer locations2070R, 2072R and at least two left load transfer locations 2070L, 2072Lare located on one side of a horizontal plane HP that bisects the endeffector 1300. As illustrated in FIG. 13, the two right load transferlocations 2070R, 2072R are located on an opposite side of vertical planeVP from the two left load transfer locations 2070L, 2072L. Also in atleast one arrangement, the third right load transfer location 2074R andthe fourth right load transfer location 2076R are located on an oppositeside of the horizontal plane HP from the first right load transferlocation 2070R and the second right load transfer location 2072R.Similarly, third left load transfer location 2074L and the fourth leftload transfer location 2076L are located on a opposite side of thehorizontal plane HP from the first left load transfer location 2070L andthe second left load transfer location 2072L. The right load transferlocations 2074R, 2076R are located on an opposite side of vertical planeVP from the two left load transfer locations 2074L, 2076L. As can beseen in FIGS. 6 and 10, the load transfer locations may be formed byscalloped or relieved areas 2080, 2082, 2084 so that the load transferlocations comprise corners formed from adjoining surfaces. Other loadtransfer location shapes are contemplated.

FIGS. 14 and 15 illustrate the anvil 2000 and the end effector closuretube 3050 in an “over-closed” state that is created as the end effectorclosure tube 3050 is advanced further distally after the anvil 2000 hasattained the closed position. In at least one example, the anvil 2000 isin an “over-closed state” when a distal end portion 2003 of the bodyportion 2002 of the anvil 2000 is in contact with the cartridge deck ofthe staple cartridge that is operably supported with the elongatechannel 1310. See FIG. 14. Continued distal advancement of the endeffector closure tube 3050 after the anvil 2000 has attained the closedposition may significantly increase the hoop stress formed in the endeffector closure tube 3050 which may cause the end effector closure tubeto effectually fail or vertically elongate which can detrimentallyeffect the proper closure of the anvil when used in future applications.As be seen in FIG. 15, the first right amount of clearance CR₁ and thefirst left amount of clearance CL₁ may each have a clearance width CW₁that is located on a common side of the horizontal plane HP. The secondright amount of clearance CR₂, and the second left amount of clearanceCL₂ each span across the horizontal plane HP. Stated another way,portions of the second right amount of clearance CR₂ are located on eachside of the horizontal plane HP and portions of the second left amountof clearance CL₂ are located on each side of the horizontal plane HP.

Forming at least two discrete load transfer locations located on eachside of the vertical plane may reduce the amount of detrimental hoopstresses established in the end effector closure tube 3050 as it isdistally moved into the over-closed position. By forming at least threeload transfer locations located on each side of the vertical plane mayfurther reduce the amount of detrimental hoop stresses established inthe end effector closure tube 3050 as it is distally moved into theover-closed position. Forming at least four load transfer locationslocated on each side of the vertical plane may further reduce the amountof detrimental hoop stresses established in the end effector closuretube 3050 as it is distally moved into the over-closed position. Sucharrangements therefor enable the end effector closure tube 3050 to bemade with a constant wall thickness as described above, which may reducethe amount of manufacturing costs associated with manufacturing the endeffector closure tube.

FIGS. 16-22 illustrate an alternative anvil 2000′ that is substantiallyidentical to anvil 2000 described above expect for the differencesdiscussed below. As can be seen in FIG. 16, the anvil mounting portion2010′ is formed with continuous arcuate anvil camming surfaces 2020′that are not interrupted by any load transfer locations. FIGS. 17 and 18illustrate the anvil 2000′ in a fully open position. As can be seen inFIG. 17, the end effector closure tube 3050′ is in its proximal mostposition when the “second jaw” or anvil 2000′ is in its fully openposition. When in that position, the end effector closure tube 3050′ isnot applying any closure forces to the cam closure surfaces 2020′.

FIG. 23 illustrates one form of an end effector closure tube 3050′ thatmay be identical to the end effector closure tube 3050 described above,except for the differences noted below. The end effector closure tube3050′ comprises an external surface 3074′ and an internal wall surface3076′. In at least one form, the closure tube 3050′ has a constant wallthickness WT₁ except for a segment A_(s) of the wall located at the topof the end effector closure tube 3050′ that has a thicker wall thicknessWT₂ that is greater than WT₁. Such arrangement forms a single loadtransfer location 2070′.

FIGS. 19 and 20 illustrate the positions of the end effector closuretube 3050′ and the anvil 2000′ when the anvil 2000′ is in the closedposition. As can be seen in FIG. 20, as the end effector closure tube3050′ is moved distally, the load transfer location 2070′ on the endeffector closure tube 3050′ contacts the cam surface 2034 on theproximal portion 2032 of the anvil cap 2030. The end effector closuretube 3050′ also contacts portions of the elongate channel 1310 on eachside of the vertical plane VP that bisects the end effector. The loadtransfer location 2070′ may span across the entire cam surface 2034 tocontact an upper portion of the cam surfaces 2020′ on each side of thevertical plane VP as shown in FIG. 20. When in the closed position shownin FIGS. 19 and 20, such arrangement serves to form a space 3077 betweenthe corresponding portions of the inner surface 3076′ of the endeffector closure tube 3050′ and the cam surfaces 2020′ of the anvilmounting portion 2010′ as shown in FIG. 20. The spaces 3077 each extendfrom the load transfer location 2070′ and the area wherein the innersurface 3076′ contacts the elongate channel 1310 (space distance SD).Thus, when the anvil 2000′ is moved to a closed position, there is adiscrete first load transfer location 2070′ located on one side of ahorizontal plane HP and two discrete load transfer locations 2072R′,2072L′ locations located on an opposite side of the horizontal plane HP.The discrete first load transfer location 2070′ is separated from eachof the discrete load transfer locations 2072R′, 2072L′ by spaces 3077when the anvil 2000′ is in the closed position. See FIG. 20. As can alsobe seen in FIG. 20, the load transfer locations 2072R′, 2072L′ arelocated on opposite sides of the vertical plane VP.

FIGS. 21 and 22 illustrate the interrelationship between the endeffector closure tube 3050′ and the anvil 2000′ when the end effectorclosure tube 3050′ has moved the anvil 2000′ in an over-closedorientation. As can be seen in FIG. 22, when in the over-closedposition, the end effector closure tube 3050′ contacts the anvil 2000′and the elongate channel 1310 to form a discrete load transfer location2070′ that is separated from discrete load transfer locations 2074R′,2074L′ by spaces 3079R, 3079L. The discrete load transfer location2074R′ is separated by the discrete load transfer location 2076R′ by aspace 3081R and the discrete load transfer location 2074L′ is separatedfrom a discrete load transfer location 2076L′ by a space 3081L. Thus, inthis arrangement, at least one discrete load transfer location (2070′)spans a vertical plane VP that bisects the end effector and at least twodiscrete load transfer locations span a horizontal plane HP that bisectsthe end effector. In addition, at least one discrete load transferlocation is located on each side of the horizontal plane HP and at leastone discrete load transfer location is located on each side of thevertical plane VP. Such arrangement of load transfer locations in theabove manner may help to prevent the vertical elongation of the endeffector closure tube 3050′.

FIGS. 24-30 illustrate an alternative anvil 2000″ that is substantiallyidentical to anvil 2000 described above expect for the differencesdiscussed below. As can be seen in FIG. 24, the anvil mounting portion2010″ is formed with an arcuate anvil camming surface 2020″ and rightand left notched or recessed portions 2022″. FIGS. 24 and 25 illustratethe anvil 2000″ in a fully open position. As can be seen in FIG. 24, theend effector closure tube 3050″ is in its proximal most position whenthe “second jaw” or anvil 2000″ is in its fully open position. When inthat position, the end effector closure tube 3050″ is not applying anyclosure forces to the cam closure surfaces 2020″. FIG. 30 illustratesone form of an end effector closure tube 3050″ that may be identical tothe end effector closure tube 3050 described above, except for thedifferences noted below. The end effector closure tube 3050″ comprisesan external surface 3074″ and an internal wall surface 3076″. In atleast one form, the closure tube 3050″ has a first wall thickness WT₁, asecond wall thickness WT₂, a third wall thickness WT₃, and a fourth wallthickness WT₄ that are arranged as shown in FIG. 30. In at least onearrangement, for example, WT₁<WT₂<WT₃≤WT₄. In some cases, WT₃>WT₄. Theportion of the end effector closure tube 3050″ that has a wall thicknesscorresponding to WT₄ forms a load transfer location 2070″. In theillustrated arrangement, for example, the load transfer location 2070″spans across a vertical plane VP that bisects the end effector closuretube 3050″. The portions of the end effector closure tube 3050″ thathave a wall thickness WT₃ form load transfer locations 2072R″, 2072L″.In at least one arrangement as shown in FIG. 30, the load transferlocations 2072R″, 2072L″ span across a horizontal plane HP that bisectsthe end effector closure tube 3050″.

Referring now to FIGS. 26 and 27, as the end effector closure tube 3050″is moved distally, the load transfer location 2070″ contacts the camsurface 2034 on the proximal portion 2032 of the anvil cap 2030. Theload transfer locations 2072R″, 2072L″ also contact correspondingportions of the anvil mounting portion 2010″. Also portions of the endeffector closure tube 3050″ form load transfer locations 2074R″, 2074L″that contact corresponding portions of the elongate channel 1310 to movethe anvil 2000″ to the closed position shown in FIGS. 26 and 27. When inthe closed position shown in FIGS. 26 and 27, such arrangement serves toform a space 3077″, 3079″ between the corresponding portions of theinner surface 3076″ of the end effector closure tube 3050″ and the camsurfaces 2020″ of the anvil mounting portion 2010″ as shown in FIG. 27.The spaces 3077″ are located between the load transfer location 2070″and the load transfer locations 2072R″, 2072L″. The spaces 3079″ arelocated between the load transfer locations 2072R″, 2072L″ and the loadtransfer locations 2074R, 2074L″ as shown in FIG. 27.

FIGS. 28 and 29 illustrate the interrelationship between the endeffector closure tube 3050″ and the anvil 2000″ when the end effectorclosure tube 3050″ has moved the anvil 2000″ into an over-closedorientation. As can be seen in FIG. 29, in addition to the load transferlocations 2070″, 2072R″, 2072L″, 2074R″, 2074L″, discrete load transferlocations 2076R″, 2076L″ are formed by the edge of the recessed portions2022″ formed on the anvil mounting portion 2010″. Such discrete loadtransfer locations 2076R″, 2076L″ are separated from the correspondingdiscrete load transfer locations 2072R″. 2072L″ by corresponding spaces3081″. The provision of the discrete load transfer locations in theabove manner may help to prevent the vertical elongation of the endeffector closure tube 3050″.

When using an end effector 1300 of the type and construction describedherein, a clinician manipulates the first and second jaws (the anvil2000 and the elongate channel 1310 that has a surgical staple cartridgeoperably mounted therein), to capture the tissue to be cut and stapled(the “target tissue”) therebetween. As can be seen in FIGS. 5 and 7, forexample, a surgical staple cartridge 4000 comprises a cartridge body4010 that is configured to be removably supported within the elongatechannel 1310. The cartridge body 4010 includes an elongate cartridgeslot 4016 that extends from a proximal end 4012 through the cartridgebody 4010 to a distal end portion 4014 to enable the knife member orfiring member 1920 to pass therethrough. The cartridge body 4010 furtherdefines a cartridge deck surface 4020 on each side of the elongate slot4016. A plurality of staple cavities 4022 are provided in the cartridgebody 4010 on each side of the elongate slot 4016. Each cavity 4022 opensthrough the deck surface 4020 to removably support a surgical staple orstaples therein. In at least one cartridge arrangement, three lines ofstaple cavities 4022 are provided on each side of the elongate slot4016. The lines are formed such that the staples in a center line arestaggered relative to the staples in the two adjacent outer lines. Thestaples are supported on staple drivers that are movably supportedwithin each staple cavity. In at least some arrangements, the stapledrivers are arranged to be contacted or “fired” upward when contacted bya cam member or camming portions associated with the knife member 1920,for example. In some arrangements, a wedge sled or camming sled ismovably supported in the cartridge body and is adapted to be axiallydisplaced through the cartridge body as the knife member 1920 is axiallydeployed through the cartridge from the proximal end portion 4012 to thedistal end portion 4014 of the cartridge body 4010. The wedge sledincludes a camming member or wedge associated with each line of staplecavities so as to serially deploy the staple drivers supported therein.As the cam contacts a staple driver, the driver is driven upwardlywithin the staple cavity driving the staple or staples supported thereonout of the staple cavity through the clamped tissue and into formingcontact with the staple-forming undersurface of the anvil. The wedgesled or camming member is located distal to the knife or tissue cuttingedge of the knife or firing member 1920, so that the tissue is stapledprior to be severed by the tissue cutting edge.

When the clinician initially locates the target tissue between the anviland the staple cartridge, it is important that the target tissue belocated so that the knife does not cut into the target tissue unless itis first stapled. In previous anvil arrangements, tissue stops areprovided on the proximal end of the anvil body to prevent the targettissue from moving proximally past the proximal most staple pockets inthe staple cartridge. Such tissue stops form abrupt proximal ends thatconfront or face the distal end of the end effector closure tube. As theclosure tube is moved distally to close the anvil, tissue extendingoutward from between the anvil and the cartridge occasionally willbecome undesirably pinned or pinched between the proximal ends of thetissue stops and the distal end of the end effector closure tube. Theexamples disclosed below are configured to minimize the possibility oftissue being pinched between the tissue stops and the end effectorclosure tube when the anvil is being moved to the closed and over-closedpositions in the various manners described herein.

Turning to FIG. 7, for example, the staple cartridge 4000 includesstaples (not shown) that are removably supported or stored in each ofthe proximal most staple cavities 4022P located in the lines of staplecavities 4022 located in the cartridge body 4010 on each side of theelongate slot 4016.

In various circumstances, to prevent the target tissue from beingclamped proximal to the staples in the proximal most staple cavities4022P, the anvil 2000 includes two tissue stop members 2040 thatprotrude downwardly past the staple-forming undersurface on each side ofthe anvil body. When the anvil is in a closed position or in anover-closed position, each of the tissue stop members 2040 protrudedownwardly on each side of the cartridge body 4010. FIG. 7 illustratesthe anvil 2000 in an open configuration. As can be seen in that Figure,each of the tissue stops 2040 extend below the cartridge deck surface toprevent the target tissue from extending proximally past the staples inthe proximal most staple cavities 4022P. As can be seen in FIGS. 7, 31and 32, in at least one arrangement, the tissue stops 2040 areintegrally formed with the anvil body portion 2002. The anvil bodyportion 2002 and the proximal ends of the tissue stops 2040 extendslightly above the corresponding camming surfaces 2020 formed on theanvil mounting portion 2010. In the illustrated example, the proximalends of the tissue stops 2040 are segmented into an upper proximal endportion 2042, a lower proximal end portion 2043 and a bottom proximalend portion 2044. See FIGS. 31 and 32. As can also be seen in FIGS. 31and 32, an angled surface or chamfer surface 2045 is formed between theupper proximal end portion 2042 and the camming surface 2020 on theanvil mounting portion. An angled surface or chamfer surface 2046 isformed between the lower proximal end portion 2043 and the cammingsurface 2020 and an angled surface or chamfer surface 2047 is formedbetween the bottom proximal end portion 2044 and the camming surface2020. In the illustrated arrangement wherein scalloped or relieved areas2080, 2082, 2084 are formed in the anvil mounting portion 2010, thechamfer 2045 corresponds to the relieved area 2080. See FIG. 33. Thelower proximal end portion 2043 and accompanying chamfer 2046 correspondto relieved area 2082 and the bottom proximal end portion 2044 andaccompanying chamfer 2047 corresponds to relieved area 2084.

As discussed above, the anvil 2000 is moved from a fully open positionto the closed position and an over-closed position by the axiallymovable end effector closure tube 3050. FIGS. 31 and 33 illustrate theposition of the end effector closure tube 3050 relative to the tissuestops 2040 when the anvil 2000 is in the closed position. As can be seenin FIG. 33, the upper proximal end portion 2042 and accompanying chamfer2045 are approximately parallel to a corresponding portion of a distalend 3051 of the end effector closure tube 3050. To reduce a possibilityof tissue being inadvertently pinched between the tissue stops 2040 andthe distal end 3051 of the end effector closure tube 3050, the lowerproximal end portion 2043 and the bottom proximal end portion 2044 ofthe tissue stop 2040 and the corresponding chamfers 2046 and 2047 angleaway from the distal end 3051 of the end effector closure tube 3050.This arrangement has the practical effect of increasing a distancebetween the portion of the tissue stop and the end effector closure tubethat may most likely encounter adjacent tissue.

FIG. 33 is an enlarged view of a portion of the end effector depicted inFIG. 31 wherein the anvil 2000 is in a closed position. When in thatposition, the upper proximal end portion 2042 of each tissue stops 2040is located a first tissue distance TD₁ from the distal end 3051 of theend effector closure tube 3050. The bottom proximal end portion 2044 ofeach tissue stop 2040 is located a second tissue distance TD₂ from thedistal end 3051 of the end effector closure tube 3050. As can be seen inthat Figure, TD₂>TD₁. FIGS. 32 and 34 depict the anvil 2000 in anover-closed position. The first tissue distance TD₁′ between the upperproximal end portion 2042 of each tissue stop 2040 is still slightlyless than the second tissue distance TD₂′ between the bottom proximalend portion 2044 of each tissue stop 2040 and the distal end 3051 of theend effector closure tube 3050 which will still reduce the likelihood oftissue pinch therebetween. In at least one example, TD₂ and/or TD₂′ maybe approximately ten thousands of an inch to approximately twenty-fivethousands of an inch. However, other gaps may be attained. Also, theinclusion of the chamfered surfaces 2045, 2046 and 2047 may help tolessen the likelihood of pinching tissue between the tissue stops 2040and the distal end 3051 of the end effector closure tube 3050 when theanvil 200 is moved to the closed and over-closed positions. The personof ordinary skill in the art will appreciate that the above-describedtissue stop configurations will also work with other forms of endeffector closure tube and closure member arrangements.

FIGS. 35-38 illustrate another anvil embodiment 5000 that is identicalto anvil 2000 described above except for the differences relating totissue stops 5040. Tissue stops 5040 may be identical to tissue stops2040 except that proximal end portions 5042, 5043, 5044 of each tissuestop and the accompanying chamfer surfaces 5045, 5046, 5047 areapproximately parallel to the distal end 5031 of the end effectorclosure tube 5030. End effector closure tube 5050 may otherwise beidentical to end effector closure tube 3050 described above, except forthe differences discussed below. FIGS. 35 and 36 illustrate the anvil5000 in the closed position. In this arrangement, an area that mayotherwise be susceptible to pinching tissue is the edge of the bottomproximal end portion 5044 and the confronting portion of the distal end5031 of the end effector closure tube 5050. To alleviate and minimizesuch possibility, a relieved area 5060 is formed in the distal end 5031of the end effector closure tube 5030 that confronts or, stated anotherway, is opposite from the bottom proximal end 5044 of each of the tissuestops 5040. In the illustrated example, each relieved area 5060comprises an arcuate notch 5062 that is formed in the portion of thedistal end 5031 of the end effector closure tube 5030 corresponding tothe bottom proximal end portion 5044 of each tissue stop 5040. In theillustrated arrangements, for example, the bottom proximal end portion5044 of each of the tissue stops 5040 terminates in a bottom corner 5070and the apex or bottom 5064 is directly across from the bottom corner5070 when the end effector closure tube 5050 is in the positioncorresponding to the closed position of the anvil 5000. Other notchshapes, however, may be employed.

FIG. 36 is an enlarged view of a portion of the end effector depicted inFIG. 35 wherein the anvil 5000 is in a closed position. When in thatposition, the upper proximal end portion 5042, the lower proximal endportion 5043 and the bottom proximal end portion 5044 of each tissuestop 5040 are located a first tissue distance TD₁ from the distal end3051 of the end effector closure tube 5050. The bottom proximal endportion 5044 of each tissue stop 5040 is located a second tissuedistance TD₂ from the apex or bottom 5064 of the notch 5062 in thedistal end 5051 of the end effector closure tube 5050. As can be seen inthat Figure, TD₂>TD₁. FIGS. 37 and 38 depict the anvil 5000 in anover-closed position. The first tissue distance TD₁′ between the bottomproximal end portion 5044 of each tissue stop 5040 is still less thanthe second tissue distance TD₂′ between the bottom proximal end portion5044 of each tissue stop 2040 and the apex 5064 of the correspondingnotch 5062 in the distal end 5051 of the end effector closure tube 5050which will still reduce the likelihood of tissue pinch therebetween.Also, the inclusion of the chamfered surfaces 5045, 5046 and 5047 mayhelp to lessen the likelihood of pinching tissue between the tissuestops 5040 and the distal end 5051 of the end effector closure tube 5050when the anvil 5000 is moved to the closed and over-closed positions.The person of ordinary skill in the art will appreciate that theabove-described tissue stop configurations will also work with otherforms of end effector closure tube and closure member arrangements.

FIG. 39 illustrates a previous surgical staple cartridge 4000 thatincludes a cartridge body 4010 that is configured to be removablysupported within the elongate channel 1310. The cartridge body 4010includes an elongate cartridge slot 4016 that extends from a proximalend 4012 through the cartridge body 4010 to a distal end portion 4014 toenable the knife member or firing member 1920 (FIG. 5) to passtherethrough. The cartridge body 4010 further defines a cartridge decksurface 4020 on each side of the elongate slot 4016. See FIG. 39. Aplurality of staple cavities 4022 are provided in the cartridge body4010 on each side of the elongate slot 4016. Each cavity 4022 opensthrough the deck surface 4020 to removably support a surgical staple orstaples therein. In at least one cartridge arrangement, three lines ofstaple cavities 4022 are provided on each side of the elongate slot4016. In the illustrated example, the lines are formed such that thestaples in a center line are staggered relative to the staples in thetwo adjacent outer lines. The staples are supported on staple driversthat are movably supported within each staple cavity. In at least somearrangements, the staple drivers are arranged to be contacted or “fired”upward when contacted by a cam member or camming portions associatedwith the knife member 1920, for example. In some arrangements, a “wedge”sled or camming sled is movably supported in the cartridge body 4010 andis adapted to be axially displaced through the cartridge body 4010 asthe knife member 1920 is axially deployed through the cartridge from theproximal end portion 4012 to the distal end portion 4014 of thecartridge body 4010. The wedge sled includes a camming member or “wedge”associated with each line of staple cavities so as to serially deploythe staple drivers supported therein. As the corresponding wedge or camcontacts a staple driver, the driver is driven upwardly within thestaple cavity thereby driving the staple or staples supported thereonout of the staple cavity through the clamped tissue and into formingcontact with the staple-forming undersurface of a confronting anvil ofthe end effector. The wedge sled or camming member is located distal tothe knife or tissue cutting edge of the knife or firing member 1920, sothat the tissue is stapled prior to being severed by the tissue cuttingedge on the knife or firing member.

Variations to the arrangement and/or geometry of staples in a stapleline can affect the flexibility and sealing properties of the stapleline. For example, a staple line comprised of linear aligned staples canprovide a limited amount of flexibility or stretch because the stapleline can flex or stretch between the linear staples. Consequently, alimited portion of the staple line (e.g., the portion between staples)is flexible. A staple line comprised of angularly-oriented staples canalso flex or stretch between the staples. However, theangularly-oriented staples are also able to rotate, which provides anadditional degree of stretch within the staple line. A staple linecomprised of angularly-oriented staples may be capable of stretching inexcess of 60%, for example. In certain instances, a staple linecomprised of angularly-oriented staples can stretch at least 25% or atleast 50%, for example. The arrangement of staples includes the relativeorientation of the staples and the spacing between the staples, forexample. The geometry of the staples includes the size and shape of thestaples, for example. The flexibility and sealing properties of a stapleline can change at longitudinal and/or lateral positions based on thearrangement and/or geometry of the staples. In certain instances, it isdesirable to alter the flexibility and/or sealing properties of a stapleline at one or more locations along the staple line. For example, it canbe desirable to maximize the flexibility of the staple line or a portionthereof. Additionally or alternatively, it can be desirable to minimizethe flexibility of the staple line or a portion thereof. It can also bedesirable to maximize the sealing properties of the staple line or aportion thereof. Additionally or alternatively, it can be desirable tominimize the sealing properties of the staple line or a portion thereof.

The arrangement of staple cavities in a staple cartridge corresponds tothe arrangement of staples in a staple line generated by the staplecartridge. For example, the spacing and relative orientation of staplecavities in a staple cartridge corresponds to the spacing and relativeorientation of staples in a staple line generated by the staplecartridge. In various instances, a staple cartridge can include anarrangement of staples cavities that is selected and/or designed tooptimize the flexibility and/or sealing properties of the resultantstaple line. A surgeon may select a staple cartridge having a particulararrangement of staple cavities based on the surgical procedure to beperformed and/or the properties of the tissue to be treated during thesurgical procedure, for example.

In certain instances, it can be desirable to generate a staple line withdifferent staple patterns. A staple line can include a first pattern ofstaples for a first portion thereof and a second pattern of staples fora second portion thereof. The first pattern and the second pattern canbe longitudinally offset. For example, the first pattern can bepositioned at the proximal or distal end of the staple line. In otherinstances, the first pattern and the second pattern can be laterallyoffset and, in still other instances, the first pattern and the secondpattern can be laterally offset and longitudinally offset. A staple linecan include at least two different patterns of staples.

In certain instances, the majority of staples in a staple line can forma major pattern and other staples in the staple line can form one ormore minor patterns. The major pattern can span a significant portion ofthe staple line and can include a longitudinally-repetitive sub-pattern.In certain instances, the minor pattern, or irregularity, can deviatefrom the major pattern. The minor pattern can be an anomaly at one ormore locations along the length of the staple line, for example. Thedifferent patterns in a staple line can be configured to producedifferent properties at predefined locations. For example, the majorpattern can be a highly flexible or elastic pattern, which can permitextensive stretching of the stapled tissue, and the minor pattern can beless flexible or less elastic. It can be desirable for the majority ofthe staple line to be highly flexible and for one or more limitedportions to be less flexible, for example. In other instances, the minorpattern can be more flexible than the major pattern. In certaininstances, because the minor pattern extends along a shorter portion ofthe staple line, the flexibility of the minor pattern may not impact, ormay not significantly impact, the overall flexibility of the entirestaple line. U.S. patent application Ser. No. 15/385,389, entitledSTAPLE CARTRIDGE AND ARRANGEMENTS OF STAPLES AND STAPLE CAVITIESTHEREIN, now U.S. Patent Application Publication No. 2018/0168629, theentire disclosure of which is hereby incorporated by reference hereindiscloses various staple cartridge and staple driver arrangements. U.S.Pat. No. 9,801,627, entitled FASTENER CARTRIDGE FOR CREATING FLEXIBLESTAPLE LINES, the entire disclosure of which is hereby incorporated byreference herein discloses various cartridge an anvil arrangements forcreating flexible lines of surgical staples.

Referring again to FIG. 39, the majority of the staple cavities 4022 inthe cartridge 4000 are arranged in a first pattern, or major pattern,4030. The first pattern 4030 is a longitudinally-repetitive pattern ofangularly-oriented staple cavities 4022. Longitudinally-repetitivepatterns are patterns in which a sub-pattern or arrangement islongitudinally repeated. For example, an arrangement of three staplecavities on each side of the slot 4016 (an inner staple cavity, anintermediate staple cavity, and an outer staple cavity) can be repeatedalong at least a portion of the length of the staple cartridge body4010. Various longitudinally-repetitive patterns of angularly-orientedstaples cavities are described in U.S. patent application Ser. No.14/498,145, filed Sep. 26, 2014, now U.S. Patent Application PublicationNo. 2016/0089142, entitled METHOD FOR CREATING A FLEXIBLE STAPLE LINE,which is hereby incorporated by reference herein in its entirety. Theopenings 4024 of the staple cavities 4022 in the first pattern 4030 forma herringbone pattern having six rows of angularly-oriented staplecavity openings 4024 in the cartridge deck surface 4020. An inner row4026 a, an intermediate row 4026 b, and an outer row 4026 c of staplecavities 4022 are positioned on each side of the slot 4016.

Each staple cavity opening 4024 has a proximal end 4027 and a distal end4028. The proximal end 4027 and the distal end 4028 of the staplecavities 4022 in the first pattern 4030 are laterally offset. Stateddifferently, each staple cavity 4022 in the first pattern 4030 isangularly oriented relative to a longitudinal staple cartridge axis SCA.A cavity axis CA extends between the proximal end 4027 and the distalend 4028 of each opening 4024. The cavity axes CA are obliquely orientedrelative to the slot 4016. More specifically, the openings 4024 in theinner rows 4026 a of staple cavities 4022 and the outer rows 4026 c ofstaple cavities 4022 are oriented at 45 degrees, or about 45 degrees,relative to the longitudinal staple cartridge axis SCA, and the openings4024 in the intermediate rows 4026 b of staple cavities 4022 areoriented at 90 degrees, or about 90 degrees, relative to the openings4024 of the inner rows 4026 a and the outer rows 4026 c.

In the example of FIG. 39, certain staple cavities in the cartridge body4010 are oriented at an angle that is anomalous or irregular withrespect to the staple cavities 4022 in the first pattern 4030. Morespecifically, the angular orientation of proximal staple cavities 4022a, 4022 b, 4022 c, and 4022 d and distal staples cavities 4022 e, 4022f, 4022 g, and 4022 h does not conform to the herringbone arrangement ofthe staple cavities 4022 in the first pattern 4030. Rather, the proximalstaple cavities 4022 a-4022 d and the distal staple cavities 4022 e-4022h are angularly offset from the staple cavities 4022 in the firstpattern 4030. The proximal staple cavities 4022 a, 4022 b, 4022 c, and4022 d are obliquely oriented relative to the staples cavities 4022 inthe first pattern 4030, and the distal staple cavities 4022 e, 4022 f,4022 g, and 4022 h are also obliquely oriented relative to the staplescavities 4022 in the first pattern 4030. The proximal and distal staplecavities 4022 a-4022 h are oriented parallel to the slot 4016 and to thelongitudinal staple cartridge axis SCA.

The proximal staple cavities 4022 a-4022 d form a proximal pattern 4040that is distinct from the first pattern 4030, and the distal staplecavities 4022 e-4022 h form a distal pattern 4042 that is also distinctfrom the first pattern 4030. In the depicted arrangement, the proximalpattern 4040 includes a first pair of parallel, longitudinally-alignedstaple cavities 4022 a, 4022 b on a first side of the slot 4016 and asecond pair of parallel, longitudinally-aligned staple cavities 4022 c,4022 d on a second side of the longitudinal slot 4016. The distalpattern 4042 also includes a first pair of parallel,longitudinally-aligned staple cavities 4022 e, 4022 f on the first sideof the longitudinal slot 4016 and a second pair of parallel,longitudinally-aligned staple cavities 4022 g, 4022 h on the second sideof the longitudinal slot 4016. In other instances, the distal pattern4042 can be different from the proximal pattern 4040.

The proximal pattern 4040 and the distal pattern 4042 are symmetricrelative to the longitudinal staple cartridge axis SCA. In otherinstances, the proximal pattern 4040 and/or the distal pattern 4042 canbe asymmetric relative to the longitudinal staple cartridge axis SCA.For example, the staple cavities 4022 e and 4022 f can be longitudinallyoffset from the staple cavities 4022 g and 4022 h and/or the staplecavities 4022 a and 4022 b can be longitudinally offset from the staplecavities 4022 c and 4022 d. Additionally or alternatively, in certaininstances, the staple cartridge body 4010 can include either theproximal pattern 4040 or the distal pattern 4042. In other instances,the staple cavities 4022 defined in the staple cartridge body 4010 caninclude additional and/or different patterns of staple cavities 4022.

As can be further seen in FIG. 39, atraumatic extenders 4050 extend orprotrude from the deck surface 4020 around a portion of the staplecavities 4022 in the first pattern 4030. The atraumatic extenders 4050surround the proximal and distal ends 4027 and 4028, respectively, ofthe openings 4024 of the staple cavities 4022 in the first pattern 4030.The atraumatic extenders 4050 may be configured to grip tissue that isclamped by the end effector. Additionally or alternatively, in certaininstances, the tips of the staple legs can protrude from the cartridgebody 4010. In such instances, the atraumatic extenders 4050 may beconfigured to extend flush with and/or beyond the tips of the staplelegs to prevent the tips from prematurely penetrating tissue.Consequently, larger staples, e.g., staples having longer legs, can bepositioned in the staple cavities 4022 having atraumatic extenders 4050positioned therearound. For example, referring again to FIG. 39, largerstaples can be positioned in the staple cavities 4022 in the firstpattern 4030 than the staples in the staple cavities in the proximalpattern 4040 and the distal pattern 4042 without risking prematurepiercing of tissue by the longer staple legs. In certain instances,atraumatic extenders 4050 can be positioned around staples cavities 4022in the proximal pattern 4040 and/or the distal pattern 4042, and largerstaples can be positioned in one of more of those staple cavities 4022a-4022 h, as well.

The staple cartridge body 4010 can be configured to generate a stapleline having different properties along the length thereof. A staple line4060 generated by the staple cartridge body 4010 and embedded in tissueT is depicted in FIG. 40. The staple line 4060 is comprised of staples4062, and an exemplary staple 4062 for use with various staplecartridges described herein is depicted in FIG. 41. The staple 4062 canbe comprised of a bent wire, for example. The wire can have a diameterof 0.0079 inches, or approximately 0.0079 inches. In other instances,the wire can have a diameter of 0.0089 inches, or approximately 0.0089inches. In still other instances, the wire can have a diameter of0.0094, or approximately 0.0094 inches. In certain instances, the wirecan have a diameter of less than 0.0079 inches or more than 0.0094inches. The reader will appreciate that the diameter of the wire candictate the diameter of the staple. The staple 4062 is a substantiallyU-shaped staple having a base 4064, a first leg 4066 extending from afirst end of the base 4064, and a second leg 4068 extending from asecond end of the base 4064. The first leg 4066 is substantiallyparallel to the second leg 4068 and substantially perpendicular to thebase 4064. When implanted in tissue T, the angular orientation of thebase 4064 corresponds to the angular orientation of the staple cavityopening 4024 from which the staple 4062 was fired.

Another exemplary staple 4070 that may be used with various staplecartridges described herein is depicted in FIG. 42. The staple 4070 is asubstantially “V-shaped” staple having a base 4072, a first leg 4074extending from a first end of the base 4072, and a second leg 4076extending from a second end of the base 4072. The first leg 4074 isobliquely oriented relative to the second leg 4076 and the base 4072.When implanted in tissue T, the orientation of the base 4072 correspondsto the orientation of the staple cavity opening 4024 from which thestaple 4070 was fired. The reader will appreciate that staples havingdifferent geometries can also be fired from the staple cartridgesdescribed herein.

Referring again to FIG. 40, the staple line 4060 includes a firstportion 4061, a proximal portion 4063, and a distal portion 4065. Thefirst portion 4061 is generated from the first pattern, or majorpattern, 4030 and extends along a substantial portion of the staple line4030. Owing to the angular orientation of the staples 4062 in the firstportion 4030, the first portion 4061 is substantially flexible orcompliant. For example, because the angularly-oriented staples 4062 canrotate within the stapled tissue T while minimizing trauma to the tissueT, the first portion 4061 is configured to stretch or extendlongitudinally and/or laterally as the stapled tissue stretches.

The proximal portion 4063 is generated from the proximal pattern 4040and forms the proximal end of the staple line 4060. The distal portion4065 is generated from the distal pattern 4042 and forms the distal endof the staple line 4060. Owing to the parallel orientation of thestaples 4062 in the proximal portion 4063 and the distal portion 4065 ofthe staple line 4060, the proximal portion 4063 and the distal portion4065 of the staple line 4060 can be less flexible than the first portion4061. However, the reduced flexibility of the proximal portion 4063 andthe distal portion 4065 may not impact, or not substantially impact, theoverall flexibility of the staple line 4060. Moreover, as describedherein, the proximal portion 4063 and the distal portion 4065 may notextend adjacent to the cutline and, in certain instances, the proximalportion 4063 may be absent or missing from the staple line 4060.

As described herein, staples are removably positioned in a staplecartridge and fired from the staple cartridge during use. In variousinstances, the staples can be driven out of staple cavities in thestaple cartridge and into forming contact with an anvil. For example, afiring element can translate through the staple cartridge during afiring stroke to drive the staples from the staple cartridge toward ananvil. In certain instances, the staples can be supported by stapledrivers and the firing element can lift the staple drivers to eject orremove the staples from the staple cartridge.

An anvil can include a staple-forming undersurface having staple-formingpockets defined therein. In certain instances, the staple-formingpockets can be stamped in the anvil. For example, the staple-formingpockets can be coined in a flat surface of the anvil. The reader willappreciate that certain features of the staple-forming pockets can be adeliberate consequence of a coining process. For example, a certaindegree of rounding at corners and/or edges of the staple-forming producecan be an intentional result of the coining process. Such features canalso be designed to better form the staples to their formedconfigurations, including staples that become skewed and/or otherwisemisaligned during deployment.

Each staple in the staple cartridge can be aligned with a staple-formingpocket of the anvil. In other words, the arrangement of staple cavitiesand staples in a staple cartridge for an end effector can correspond ormatch the arrangement of staple-forming pockets in an anvil of the endeffector. More specifically, the angular orientation of each staplecavity can match the angular orientation of the respectivestaple-forming pocket. For example, when the staple cavities arearranged in a herringbone pattern, the staple-forming pockets can alsobe arranged in a herringbone pattern.

When staples are driven from the staple cartridge and into formingcontact with the anvil, the staples can be formed into a “fired”configuration. In various instances, the fired configuration can be a“B-form” configuration, in which the tips of the staple legs are benttoward the staple base or crown to form a capital letter B havingsymmetrical upper and lower loops. In other instances, the firedconfiguration can be a modified B-form, such as a skewed B-formconfiguration, in which at least a portion of a staple leg torques outof plane with the staple base, or an asymmetrical B-form configuration,in which the upper and lower loops of the capital letter B areasymmetric. Tissue can be captured or clamped within the formed staple.

The arrangement of staples and/or staple cavities in a staple cartridgecan be configured to optimize the corresponding arrangement ofstaple-forming pockets in the forming surface of a complementary anvil.For example, the angular orientation and spacing of staples in a staplecartridge can be designed to optimize the forming surface of an anvil.In certain instances, the footprint of the staple-forming pockets in ananvil can be limited by the geometry of the anvil. In instances in whichthe staple-forming pockets are obliquely-oriented relative to alongitudinal axis, the width of the anvil can limit the size and spacingof the obliquely-oriented staple-forming pockets. For example, the widthof an intermediate row of staple-forming pockets can define a minimumdistance between a first row (e.g. an outer row) on one side of theintermediate row and a second row (e.g. an inner row) on the other sideof the intermediate row. Moreover, the rows of staple-forming pocketsare confined between an inside edge on the anvil, such as a knife slot,and an outside edge of the anvil.

In various instances, the pockets can be adjacently nested along astaple-forming undersurface of the anvil. For example, an intermediatepocket can be nested between an inner pocket and an outer pocket. Theangular orientation of the pockets can vary row-to-row to facilitate thenesting thereof. For example, the staple-forming pockets in an inner rowcan be oriented at a first angle, the staple-forming pockets in anintermediate row can be oriented at a second angle, and thestaple-forming pockets in an outer row can be oriented at a third angle.The first angle, the second angle, and the third angle can be different,which can facilitate the close arrangement of the staple-formingpockets.

Referring again to the previous staple cartridge depicted in FIG. 39 andother previous staple cartridges disclosed in, for example, U.S. Pat.No. 9,801,627, entitled FASTENER CARTRIDGE FOR CREATING FLEXIBLE STAPLELINES and/or U.S. patent application Ser. No. 14/498,145, filed Sep. 26,2014, now U.S. Patent Application Publication No. 2016/0089142, entitledMETHOD FOR CREATING A FLEXIBLE STAPLE LINE, the varying angles of thestaples and the staple cavities in each row can be selected to optimizethe nesting of the staple-forming pockets in a complementary anvil. Foreach such staple cartridge, a complementary anvil can be configured tohave a corresponding arrangement of staple-forming pockets. Moreover,the staple-forming pockets in the complementary anvils can be largerthan the staple cavities in an effort to facilitate the staple legs landor fall within the staple-forming pockets. For example, the staple legsmay be biased outward, such as in the case of V-shaped staples (see FIG.42) and the larger footprint of the staple-forming pockets can catch theoutwardly-biased staple legs during firing. In various instances, thestaple-forming pockets can be 0.005 inches to 0.015 inches longer thanthe corresponding staple cavities and/or staples. Additionally oralternatively, the staple-receiving cups of each staple-forming pocketcan be 0.005 inches to 0.015 inches wider than the corresponding staplecavities. In other instances, the difference in length and/or width canbe less than 0.005 inches or more than 0.015 inches.

In instances in which the size of the staples varies within a staplecartridge, the size of the staple-forming pockets can corresponding varywithin a complementary anvil. Varying the size of the staple-formingpockets can further facilitate the nesting thereof. For example, ininstances in which staple-forming pockets in an intermediate row areshorter than the staple-forming pockets in an inner row or an outer row,the width of the intermediate row of staple-forming pockets can bereduced, which can minimize the requisite spacing between the inner rowand the outer row.

The spacing of the staple-forming pockets can also be configured tooptimize the nesting thereof. For example, the pockets arranged in aninner row can be longitudinally staggered relative to the pocketsarranged in an outer row. Moreover, the pockets in the inner row canpartially longitudinally overlap the pockets in the outer row. Thepockets in an intermediate row can be longitudinally staggered relativeto the pockets in the inner row and the pockets in the outer row. Forexample, the pockets in the intermediate row can be equidistantlylongitudinally offset from the pockets in the outer row and the pocketsin the inner row.

FIGS. 43-46 depict an anvil or portions of an anvil 6000. In theillustrated example, the anvil 6000 includes an elongate body portion6010 and an anvil mounting portion 6020. See FIG. 43. The anvil mountingportion 6020 in this example includes a pair of anvil trunnions or pivotmembers 6022 that facilitate pivotal support of the anvil 6000 on anelongate channel that supports a staple cartridge therein in the variousmanners discussed herein. A pair of tissue stops 6024 extend downwardfrom the anvil mounting portion 6020 and serve to properly locate ororient the target tissue clamped between the anvil and the staplecartridge relative to the proximal most staples stored within thecartridge. Such arrangement serves to ensure that the proximal staplesare first fired into the target tissue before the tissue gets severed bythe tissue cutting edge on the firing member. An elongate slot 6026extends along the longitudinal axis LA through the anvil mountingportion 6020 and the elongate body portion 6010 to facilitate passage ofthe knife or firing member therethrough.

The anvil body 6010 includes a staple-forming undersurface generallydesignated as 6030 through which the elongate slot 6026 passes. Thestaple-forming undersurface 6030 serves to form ledges 6032, 6034 oneach side of the slot 6026 within the anvil body 6010 for slidingengagement by protrusions formed on or attached to the knife of firingmember that passes through the slot 6026 during the staple firing andtissue cutting processes. The staple-forming undersurface 6030 comprisesplanar surface portions 6040 that may be referred to herein as“non-forming surface portions” on each side of the slot 6026 that eachhave a plurality of staple-forming pockets 6060 formed therein. See FIG.44. The anvil 6000 is generally complementary to the particular staplecartridge supported within the elongate channel. For example, thearrangement of staple-forming pockets 6060 in the anvil 6000 cancorrespond to the arrangement of staples and staple cavities in thestaple cartridge supported in the elongate channel. The forming ratio ofthe staple-forming undersurface 6030 can be optimized. By optimizing theforming ratio, more staples can be formed and/or formed to their desiredconfigurations. In certain instances, the surface area of thenon-forming surface portions 6040 of the anvil 6000 can be minimizedwith respect to the staple-forming pockets 6060. Additionally oralternatively, the footprint of the staple-forming pockets 6060 can beextended or enlarged to maximize the portion of the staple-formingundersurface 6030 that is designed to catch and form the staples.

In the illustrated arrangement, the staple-forming pockets 6060 depictedin FIGS. 43-46 are arranged in three rows 6050 a, 6050 b, 6050 c on afirst side of the longitudinal slot 6026. The first row 6050 a is anouter row, the second row 6050 b is an intermediate row and third row6050 c is an inner row. Outer pockets 6060 a are positioned in the outerrow 6050 a, intermediate pockets 6060 b are positioned in theintermediate row 6050 b, and inner pockets 6060 c are positioned in theinner row 6050 c that is closest the slot 6026. The pockets 6060 a-c arearranged in a herringbone arrangement along the staple-formingundersurface 6030 of the anvil 6000. In at least one instance, thepockets 6060 a-c on the opposing side of the slot 6026 can form a mirrorimage reflection of the pockets 6060 a-c on the first side of thelongitudinal slot 6026. In other instances, the arrangement of pockets6060 in the staple-forming undersurface 6030 can be asymmetricalrelative to the slot 6026 and, in certain instances, the anvil 6000 maynot include the longitudinal slot 6026. In various instances, thepockets 6060 can be arranged in less than or more than three rows oneach side of the slot 6026.

Each pocket 6060 a-c lies along a corresponding pocket axis and includesa perimeter 6062 a-c, which defines the boundary of the pocket 6064 a-c.Each pocket 6060 a-c also includes a proximal cup or end 6066 a-c, adistal cup or end 6068 a-c, and a neck portion 6070 a-c connecting theproximal cup 6066 a-c and the distal cup 6068 a-c. A proximal forminggroove or staple guiding groove 6072 a-c is provided in each proximalcup 6066 a-c and a distal forming groove or staple guiding groove 6074a-c is provided in each distal cup 6069 a-c. When a staple is driveninto forming contact with the staple-forming undersurface 6030 forexample, the proximal cup 6066 a-c is aligned with a proximal stapleleg, and the distal cup 6068 a-c is aligned with a distal staple leg.The tips of the staple legs are positioned and configured to land in therespective cups 6066 a-c, 6068 a-c. Stated differently, the proximal cup6066 a-c is configured to receive a proximal staple leg and the distalcup 6068 a-c is configured to receive a distal staple leg of acorresponding staple. The cups 6066 a-c and 6068 a-c as well as theforming grooves 6072 a-c, 6074 a-c are also configured to direct orfunnel the staple legs toward the pocket axis and a central portion ofthe pocket 6060 a-c, such as the neck portion 6070 a-c, and to deformthe staple legs into the formed configuration.

The geometry, spacing, and/or orientation of the pockets 6060 a-c canvary row-to-row. The pocket axis extends from the proximal cup 6066 a-c,through the neck portion 6070 a-c, and to the distal cup 6068 a-c ofeach pocket 6060 a-c. The pockets 6060 a-c in each respective row areparallel to each other. For example, the outer or first pockets 6060 aare oriented at an angle A relative to the longitudinal axis LA. SeeFIG. 45. Stated differently, the first pocket axes (e.g., FPA) of theouter pockets 6060 a are oriented at the angle A relative to thelongitudinal axis LA. The intermediate pockets 6060 b are oriented at anangle B relative to the longitudinal axis LA. Stated differently, thesecond pocket axes SPA of the intermediate pockets 6060 b are orientedat the angle B relative to the longitudinal axis LA. The inner or thirdpockets 6060 c are oriented at an angle C relative to the longitudinalaxis LA. Stated differently, the third pocket axes TPA of the innerpockets 6060 c are oriented at the angle C relative to the longitudinalaxis LA. See FIG. 45.

The angles A, B, and C may be different. In the illustrated example, theouter pockets 6060 a are approximately parallel relative to the innerpockets 6060 c. The angle A is approximately equal to the angle C. Thatis the first pocket axis FPA is approximately parallel to the thirdpocket axis TPA. The second pocket axis SPA is transverse to the firstpocket axis FPA and the third pocket axis TPA, for example, such thatthe staple-forming pockets 6060 a-c in the anvil 6000 form a herringbonepattern. The pockets 6060 a-c may be of equal length or they may havedifferent lengths. The lengths of the pockets 6060 a-c, for example, canbe selected to optimize the nesting of the pockets 6060 a-c. Forexample, the outer pockets 6060 a can be longitudinally staggeredrelative to the inner pockets 6060 c. In at least one arrangement forexample, the proximal cup 6066 b of at least some of the forming pockets6060 b in the second or intermediate row 6050 b of forming pockets isadjacent to a distal cup 6068 c of an adjacent out forming pocket 6060 cin the third or outer row 6050 c of forming pockets as shown in FIG. 45.Likewise, a distal cup 6068 b of at least some of the forming pockets6060 b in the second or intermediate row 6050 b of forming pockets 6060b are adjacent to a portion of the neck 6070 a as well as the proximalcup 6066 a of an adjacent forming cup 6060 a in the first or outer lineof forming pockets 6060 a. The arrangement of pockets 6060 a-c may beconfigured to nest the pockets 6060 a-c such that the pockets 6060 a-cfit within a predefined space. For example, in certain instances, thewidth of the anvil 6000 can be minimized or otherwise restrained to fitwithin a surgical trocar and/or within a narrow surgical field, and thearrangement of staple-forming pockets 6060 a-c (and the correspondingarrangement of staples and/or staple cavities) can fit within a narrowanvil.

The anvil 6000 may be further provided with tissue stabilizationfeatures and features that may enhance the likelihood of the properformation of the staples as they are fired into their correspondingforming pockets 6060 a-c. For example, as can be seen in FIGS. 44 and45, a plurality of anvil projections 6080 protrude upward from theplanar non-forming surface portions 6040 of the staple-formingundersurface 6030. In at least one circumstance, an outer or first anvilprotrusion 6080 is formed around each proximal end or cup 6066 a of eachforming pocket 6060 a in the first or outer row 6050 a of formingpockets 6060 a. In the illustrated arrangement, such first anvilprotrusion 6080 may be integrally formed into the non-forming surfaceportions 6040 by stamping, pressing, coining, forging, molding, metalinjection molding, electrochemical machining, etc. or attached theretoby welding, adhesive, etc. so that the first anvil protrusion 6080protrude from the planar non-forming surface portions 6040. In at leastone circumstance, a first anvil protrusion 6080 extends around at leasta portion of the proximal cup 6066 a in the corresponding first formingpocket 6060 a. The first anvil protrusion 6080 may also extend around atleast a portion of a distal cup 6068 b of the adjacent forming pocket6060 b as well as around at least a portion of the proximal cup 6066 cof an adjacent forming pocket 6060 c as shown in FIG. 45. Likewise, aninner or second anvil protrusion 6090 is formed around at least aportion of each distal end or cup 6068 c of each forming pocket 6060 cin the third or outer 6050 c of forming pockets 6060 c. In theillustrated arrangement, such second anvil protrusion 6090 may beintegrally formed into the non-forming planar surface portions 6040 bystamping, pressing, coining, forging, molding, metal injection molding,electrochemical machining, etc. or attached thereto by welding,adhesive, etc. so that the second anvil protrusions 6090 protrude fromthe planar non-forming surface portions 6040. In at least onecircumstance, a second anvil protrusion 6090 extends around at least aportion of the distal cup 6068 c in the corresponding third formingpocket 6060 c. The second anvil protrusion 6090 may also extend aroundat least a portion of a proximal cup 6066 b of the adjacent formingpocket 6060 b as well as around at least a portion of the distal cup6068 a of an adjacent first forming pocket 6060 a as shown in FIG. 45.

In at least one example, the first and second anvil protrusions 6080,6090 may be formed with at least one “contoured” staple guiding surface.The anvil 6000 depicted in FIG. 45 comprises contoured surfaces orstaple-guiding facets or surfaces 6082, 6084, 6092, 6094. As used inthis context, the term “contoured” is intended to encompass any surfacethat does not extend at a right angle (ninety degrees or about ninetydegrees) relative to the planar non-forming surface 6040. The term“contoured” may encompass a radiused surface as well as an angledsurface or facet oriented at an acute angle (less than ninety degrees)relative to the planar non-forming surface 6040.

In the illustrated arrangement, with respect to a first anvil protrusion6080, the first contoured forming surface 6082 angles inward from anupper surface 6081 of the protrusion and extends around a first portionof the perimeter of the corresponding proximal cup 6066 a. The firstcontoured forming surface 6082 transitions to an outer surface thatextends around a first end of a distal cup 6068 b of an adjacent formingpocket 6060 b. The first contoured surface 6082 then transitions to aninternal angled surface extending around an end of a proximal cup 6066 cof an adjacent staple-forming pocket 6060 c as shown in FIG. 45, forexample. Still referring to FIG. 45, a surface 6083 also angles from theupper surface 6081 of the first anvil protrusion 6080. The surface 6083forms an outer surface extending around the end of proximal cup 6066 aand then transitions into an inner angled surface that extends aroundthe distal cup 6068 b. The surface 6083 then transitions to an uppersurface that extends around the proximal cup 6066 c as shown in FIG. 45.The anvil 6000 may be used in connection with surgical staple cartridgesthat have atraumatic extenders on the deck surfaces thereof, such ascartridge 4000 described above, for example. In such instances, theanvil protrusions may be aligned or substantially aligned orapproximately aligned with a corresponding atraumatic extender orextenders on the cartridge. In other anvil arrangements, the anvilprotrusions may be oriented so as to not be aligned or be misaligned orapproximately misaligned with the atraumatic extenders on the staplecartridge. In still other arrangements, the anvil 6000 may be used inconnection with staple cartridges that do not have atraumatic extenders.

The staple-forming undersurface 6030 further includes a plurality ofsecond anvil protrusions 6090 protruding therefrom. With respect to asecond anvil protrusion 6090, a first contoured forming surface 6092angles inward from an upper surface 6091 and extends a round a portionof the perimeter of the corresponding distal cup 6068 a. The first outersurface 6092 transitions to an outer surface that angles inwardlyadjacent to a portion of the staple-forming pocket 6060 c. As can beseen in FIG. 45, the surface 6092 extends around a portion of the distal6068 c wherein it is truncated at the edge of the cartridge body. Anadditional portion 6096 of a second anvil protrusion 6060 is formedadjacent the other side of the perimeter of distal cup 6068 c as shown.An inner surface portion 6092 angles inward toward to the perimeter ofthe distal cup 6068 c as shown. Thus, in the example illustrated inFIGS. 43-46, anvil protrusions are formed or at least extend around eachforming cup portion of each staple-forming pocket 6060 a-c on thestaple-forming undersurfaces 6030 located on both sides of the elongateslot 6026 in the cartridge body 6010. Such protruding anvil formations6080, 6090 may serve to stabilize the tissue being stapled and theangled surfaces may also help guide the staple legs of the correspondingstaples into the cups of the proper staple-forming pockets duringstapling. Such use of anvil formations or tissue stabilization featureson an anvil to stabilize the tissue being cut and staples may beparticularly advantageous for anvil arrangements with herringbone pocketconfigurations designed to attain or form flexible staple lines.

FIGS. 47-49 depict an anvil 6000′ that is similar to anvil 6000discussed above, except for the differences discussed herein. Referringprimarily to FIG. 47, the anvil 6000′ includes an elongate body portion6010′ and an anvil mounting portion 6020′. The anvil mounting portion6020′ in this example includes a pair of anvil trunnions or pivotmembers 6022′ that facilitate pivotal support of the anvil 6000′ on anelongate channel that supports a staple cartridge therein in the variousmanners discussed herein. A pair of tissue stops 6024′ extend downwardfrom the anvil mounting portion 6020′ and serve to properly locate ororient the target tissue clamped between the anvil and the staplecartridge relative to the proximal most staples stored within thecartridge. Such arrangement serves to ensure that the proximal staplesare first fired into the target tissue before the tissue gets severed bythe tissue cutting edge on the firing member. An elongate slot 6026′extends along the longitudinal axis LA through the anvil mountingportion 6020′ and the elongate body portion 6010′ to facilitate passageof the knife or firing member therethrough.

The anvil body 6010′ includes a staple-forming undersurface generallydesignated as 6030′ through which the elongate slot 6026′ passes. Thestaple-forming undersurface 6030 ‘serves to form ledges 6032’, 6034′ oneach side of the slot 6026′ within the anvil body 6010′ for slidingengagement by protrusions formed on or attached to the knife of firingmember that passes through the slot 6026′ during the staple firing andtissue cutting processes. The staple-forming undersurface 6030′comprises planar portions 6040′ (FIG. 48) that may be referred to hereinas “non-forming surface portions” on each side of the slot 6026′ thateach have a plurality of staple-forming pockets 6060 a′-c′ formedtherein. The anvil 6000′ is generally complementary to the particularstaple cartridge supported within the elongate channel. For example, thearrangement of staple-forming pockets 6060 a′-c′ in the anvil 6000′ cancorrespond to the arrangement of staples and staple cavities in thestaple cartridge supported in the elongate channel. The forming ratio ofthe staple-forming undersurface 6030′ can be optimized. By optimizingthe forming ratio, more staples can be formed and/or formed to theirdesired configurations. In certain instances, the surface area of thenon-forming portions 6040′ of the anvil 6000′ can be minimized withrespect to the staple-forming pockets 6060 a′-c′. Additionally oralternatively, the footprint of the staple-forming pockets 6060 a′-c′can be extended or enlarged to maximize the portion of thestaple-forming undersurface 6030′ that is designed to catch and form thestaples.

In the illustrated arrangement, the staple-forming pockets 6060 a′-c′depicted in FIGS. 47-49 are arranged in three rows 6050 a′, 6050 b′,6050 c′ on a first side of the longitudinal slot 6026′. See FIG. 48. Thefirst row 6050 c′ is an inner row, the second row 6050 b′ is anintermediate row and third row 6050 a′ is an outer row. Inner pockets6060 c′ are positioned in the inner row 6050 c′, intermediate pockets6060 b′ are positioned in the intermediate row 6050 b′, and outerpockets 6060 c′ are positioned in the outer row 6050 c′. The pockets6060 a′-c′ are arranged in a herringbone arrangement along thestaple-forming undersurface 6030′ of the anvil 6000′. In at least oneinstance, the pockets 6060 a′-c′ on the opposing side of the slot 6026′can form a mirror image reflection of the pockets 6060 a′-c′ on thefirst side of the longitudinal slot 6026′. In other instances, thearrangement of pockets 6060 a′-c′ in the staple-forming undersurface6030′ can be asymmetrical relative to the slot 6026′ and, in certaininstances, the anvil 6000′ may not include the longitudinal slot 6026′.In various instances, the pockets 6060′ can be arranged in less than ormore than three rows on each side of the slot 6026′.

Each pocket 6060 a′-c′ includes a perimeter 6062 a′-c′, which definesthe boundary of the pocket 6060 a′-c′. Each pocket 6060 a′-c′ alsoincludes a proximal cup or end 6066 a′-c′, a distal cup or end 6068a′-c′, and a neck portion 6070 a′-c′ connecting the proximal cup 6066a′-c′ and the distal cup 6068 a′-c′. A proximal forming groove 7072a′-c′ is provided in each proximal cup 6066 a′-c′ and a distal forminggroove 6074 a′-c′ is provided in each distal cup 6068 a′-c′. When astaple is driven into forming contact with the staple-formingundersurface 6030′ for example, the proximal cup 6066 a′-c′ is alignedwith a proximal staple leg, and the distal cup 6068 a′-c′ is alignedwith a distal staple leg. The tips of the staple legs are positioned andconfigured to land in the respective cups 6066 a′-c′, 6068 a′-c′. Stateddifferently, the proximal cup 6066 a′-c′ is configured to receive aproximal staple leg and the distal cup 6068 a′-c′ is configured toreceive a distal staple leg of a corresponding staple. The cups 6066a′-c′ and 6068 a′-c′ as well as the forming grooves 6072 a′-c′, 6074a′-c′ are also configured to direct or funnel the staple legs toward thepocket axis and a central portion of the pocket 6060 a′-c′, such as theneck portion 6070 a′-c′, and to deform the staple legs into the formedconfiguration.

The geometry, spacing, and/or orientation of the pockets 6060 a′-c′ canvary row-to-row. A pocket axis extends from the proximal cup 6066 a′-c′,through the neck portion 6070 a′-c′, and to the distal cup 6068 a′-c′ ofeach pocket 6060 a′-c′. The pockets 6060 a′-c′ in each respective roware parallel. For example, the outer pockets 6060 a′ are oriented at anangle A′ relative to the longitudinal axis LA. Each outer or firstpocket 6060 a′ line along a first pocket axis FPA′ axis that is orientedat the angle A relative to the longitudinal axis LA. The intermediatepockets 6060 b′ are oriented at an angle B relative to the longitudinalaxis LA. Each second pocket 6060 b′ lies along a second pocket axis SPA′that is oriented at the angle B′ relative to the longitudinal axis LA.The inner or third pockets 6060 c′ are oriented at an angle C′ relativeto the longitudinal axis LA. Each inner pocket 6060 c′ lies along athird pocket axis TPA′ that is oriented at the angle C′ relative to thelongitudinal axis LA.

The angles A′, B′, and C′ may be different. In the illustrated example,the first or inner pockets 6060 a′ are approximately parallel relativeto the outer pockets 6060 c′. The angle A′ is approximately equal to theangle C′. That is, the first pocket axis FPA is approximately parallelto the third pocket axis TPA. The second pocket axis SPA is transverseto the first pocket axis FPA and the third pocket axis TPA, for examplesuch that the staple-forming pockets 6060 a′-c′ in the anvil 6000′ forma herringbone pattern. The pockets 6060 a′-c′ may be of equal length orthey may have different lengths. The lengths of the pockets 6060 a′-c′,for example, can be selected to optimize the nesting of the pockets 6060a′-c′. For example, the inner pockets 6060 a′ can be longitudinallystaggered relative to the outer pockets 6060 c′. In at least onearrangement for example, the proximal cup 6066 b′ of at least some ofthe forming pockets 6060 b′ in the second or intermediate row 6050 b′ offorming pockets 6060 b′ is adjacent to a distal cup 6068 c′ of anadjacent forming pocket 6060 c′ in the third or outer row 6050 c′ offorming pockets as shown in FIG. 48. Likewise, a distal cup 6068 b′ ofat least some of the forming pockets 6060 b′ in the second orintermediate row 6050 b′ of forming pockets 6060 b′ are adjacent to aportion of the neck 6070 a′ as well as the proximal cup 6066 a′ of anadjacent forming cup 6060 a′ in the first or inner line of formingpockets 6060 a′. The arrangement of pockets 6060 a′-c′ may be configuredto nest the pockets 6060 a′-c′ such that the pockets 6060 a′-c′ fitwithin a predefined space. For example, in certain instances, the widthof the anvil 6000′ can be minimized or otherwise restrained to fitwithin a surgical trocar and/or within a narrow surgical field, and thearrangement of staple-forming pockets 6060 a′-c′ (and the correspondingarrangement of staples and/or staple cavities) can fit within a narrowanvil.

The anvil 6000′ may be further provided with tissue stabilizationfeatures and features that may enhance the likelihood of the properformation of the staples as they are fired into their correspond formingpockets 6060 a′-c′. Examples of anvil protrusions are disclosed in U.S.patent application Ser. No. 14/319,014, filed Jun. 30, 2014, entitledEND EFFECTOR COMPRISING AN ANVIL INCLUDING PROJECTIONS EXTENDINGTHEREFROM, now U.S. Patent Application Publication No. US 2015/0297234,the entire disclosure of which is hereby incorporated by referenceherein. For example, as can be seen in FIG. 48, a plurality of outer orfirst anvil protrusions 7000 are formed to protrude upward from theplanar non-forming surface portions 6040′ of the staple-formingundersurface 6030′. In at least one circumstance, a first anvilprotrusion 7000 is formed adjacent a proximal side of eachstaple-forming pocket 6060 a′ in the outer row 6050 a′ of staple-formingpockets 6060 a′. In the illustrated example, each first anvil protrusion7000 is formed adjacent a corresponding first staple-forming pocket 6060a′ and a portion of the elongate slot 6026′. The first anvil protrusions7000 may be advantageously sized and shape to enhance tissue stabilityduring the clamping and stapling process and/or serve to enhance thelikelihood of the corresponding staple being properly formed duringstapling. For example, each first anvil protrusion 7000 may be shapedand sized so as to enhance and guide the staple leg of a correspondingstaple into that portion of the staple-forming pocket 6060 a′ intoforming contact with the corresponding portion of the proximal cupportion 6066 a′. In the illustrated arrangement, the first anvilprotrusions 7000 may be integrally formed into the staple-formingundersurface 6040′ by stamping, pressing, coining, forging, molding,metal injection molding, electrochemical machining, etc. or attachedthereto by welding, adhesive, etc. so that the protrusion 7000 protrudesfrom the planar surface 6040′. In at least one circumstance, a firstanvil protrusion 7000 comprises a polyhedron shape with four “first”sides 7002, 7004, 7006, 7008. The two ends 7002, 7004 aretriangular-shaped flat surfaces. The two sides 7006, 7008 extend betweenthe ends 7002, 7004 and intersect therewith to form a straight line7009. The longer side 7008 is adjacent to the proximal cup 6066 a′ andextends to the neck portion 6070 a′. See FIG. 48.

Still referring to FIG. 48, the anvil 6000′ may further include aplurality of second anvil protrusions 7010 that are formed to protrudeupward from the planar non-forming surface portions 6040′ of thestaple-forming undersurface 6030′. In at least one circumstance, asecond anvil protrusion 7010 is formed between a proximal end of acorresponding staple-forming pocket 6060 a′ and a distal end of anothercorresponding staple-forming pocket 6060 a′ in the line ofstaple-forming pockets 6050 a′. In addition, the second anvil protrusion7010 may extend along a side of an adjacent staple-forming pocket 6060b′ as shown. The second anvil protrusions 7010 may be advantageouslysized and shaped to enhance tissue stability during the clamping andstapling process and/or serve to enhance the likelihood of thecorresponding staple being properly formed during stapling. For example,each second anvil protrusion 7010 may be shaped and sized so as toenhance and guide the staple legs of staples into corresponding portionsof the staple-forming pockets 6060 a′ and 6060 b′. In the illustratedarrangement, the second anvil protrusions 7010 may be integrally formedinto the staple-forming undersurface 6040′ by stamping, pressing,coining, forging, molding, metal injection molding, electrochemicalmachining, etc. or attached thereto by welding, adhesive, etc. so thatthe second anvil protrusion 7010 protrudes from the non-forming surfaceportions 6040′. In at least one circumstance, a second anvil protrusion7010 comprises a polyhedron shape with four “second” sides 7012, 7014,7016, 7018. The two ends 7012, 7014 are triangular-shaped flat surfaces.The two sides 7016, 7018 extend between the ends 7012, 7014 andintersect therewith to form a straight line 7019. The side 7018 isadjacent to one side of the distal cup 6068 b′ and a portion of aproximal cup 6066 b′ of an adjacent staple-forming pocket 6060 b′ asshown.

Still referring to FIG. 48, the anvil 6000′ may further include aplurality of third anvil protrusions 7020 that protrude upward from thenon-forming surface portions 6040′ of the staple-forming undersurface6030′. In at least one circumstance, third anvil protrusion 7020 isformed between a proximal end of a corresponding staple-forming pocket6060 c′ and a distal end of another corresponding staple-forming pocket6060 a′ in the line of staple-forming pockets 6050 a′ as well as betweena proximal cup 6066 b′ of a staple-forming pocket 6060 b′ and a distalcup 6068 b′ of another staple-forming pocket 6060 b′ in a line ofstaple-forming pockets 6050 b′ as shown. The third anvil protrusions7020 may be advantageously sized and shaped to enhance tissue stabilityduring the clamping and stapling process and/or serve to enhance thelikelihood of the corresponding staple being properly formed duringstapling. For example, each third anvil protrusion 7020 may be shapedand sized so as to enhance and guide the staple legs of staples intocorresponding portions of the staple-forming pockets 6060 a′, 6060 b′and 6060 c′. In the illustrated arrangement, the third anvil protrusions7020 may be integrally formed into the non-forming surface portions6040′ by stamping, pressing, coining, forging, molding, metal injectionmolding, electrochemical machining, etc. or attached thereto by welding,adhesive, etc. so that the third anvil protrusion 7020 protrudes fromthe non-forming surface portions 6040′. In at least one circumstance, athird anvil protrusion 7020 comprises a polyhedron shape with four“third” sides 7022, 7024, 7026, 7028. The two ends 7022, 7024 aretriangular-shaped flat surfaces. In one arrangement, sides 7022, 2024are identical to each other. The two sides 7026, 7028 extend between theends 7022, 7024 and intersect therewith to form a straight line 7029.The sides 7026, 7028 may be identical to each other.

Also in the example depicted in FIG. 48, a plurality of fourth anvilprotrusions 7030 protrude upward from the non-forming surface portions6040′ of the staple-forming undersurface 6030′. In variouscircumstances, the fourth anvil protrusions 7030 may be identical insize and shape to the second anvil projections 7010. In at least onecircumstance, a fourth anvil protrusion 7030 comprises a polyhedronshape with four “fourth” sides 7032, 7034, 7036, 7038. For example, end7034 may be formed adjacent to a side of a proximal cup 6066 c′ of astaple-forming pocket 6060 c′ and end 7032 may be formed adjacent aportion of a distal cup 6068 c′ of an adjacent staple-forming pocket6060 c′ in the line 6050 c′ of forming pockets 6060 c′. Side 7038 may beformed adjacent to a side of a proximal cup 6066 b′ of an adjacentstaple-forming pocket 6060 b′ as shown. The sides 7032, 7034, 7036, 7038intersect to form a line 7039. The fourth anvil protrusions 7030 may beadvantageously sized and shaped to enhance tissue stability during theclamping and stapling process and/or serve to enhance the likelihood ofthe corresponding staple being properly formed during stapling. Forexample, each fourth anvil protrusion 7030 may be shaped and sized so asto enhance and guide the staple legs of staples into correspondingportions of the staple-forming pockets 6060 c′ and 6060 b′. In theillustrated arrangement, the fourth anvil protrusions 7030 may beintegrally formed into the non-forming surface portions 6040′ bystamping, pressing, coining, forging, molding, metal injection molding,electrochemical machining, etc. or attached thereto by welding,adhesive, etc. so that the protrusion 7030 protrudes therefrom.

The anvil 6000′ may further include a plurality of fifth anvilprotrusions 7050. As can be seen in FIG. 48, in at least onecircumstance, an outer or fifth anvil protrusion 7050 is formed adjacenta proximal side of a distal cup 6068 c′ of each staple-forming pocket6060 c′ in the outer row 6050 c′ of staple-forming pockets 6060 c′. Thefifth anvil protrusions 7050 may be advantageously sized and shape toenhance tissue stability during the clamping and stapling process and/orserve to enhance the likelihood of the corresponding staple beingproperly formed during stapling. For example, each fifth anvilprotrusion 7050 may be shaped and sized so as to enhance and guide thestaple leg of a corresponding staple into that portion of thestaple-forming pocket 6060 c′ into forming contact with thecorresponding portion of the proximal cup portion 6068 c′. In theillustrated arrangement, the fifth anvil protrusions 7050 may beintegrally formed in the non-forming surface portions 6040′ by stamping,pressing, coining, forging, molding, metal injection molding,electrochemical machining, etc. or attached thereto by welding,adhesive, etc. so that the fifth anvil protrusion 7050 protrudestherefrom. In at least one circumstance, a fifth anvil protrusion 7050comprises a polyhedron shape with four triangular shaped sides 7052,7054, 7056, 7058 that intersect to form a point 7059. In the illustratedexample, the first anvil protrusions 7000 may be arranged in a firstline 7001 a of first anvil protrusions 7000. The second anvilprotrusions 7010 may be arranged in a second line 7001 b of second anvilprotrusions 7010. The third anvil protrusions 7020 may be arranged in athird line 7001 c of third anvil protrusions 7020. The fourth anvilprotrusions 7030 may be arranged in a fourth line 7001 d of fourth anvilprotrusions 7030. The fifth anvil protrusions 7050 may be arranged in afifth line 7001 e of anvil protrusions 7050.

The first sides 7002, 7004, 7006, 7008 and the second sides 7012, 7014,7016, 7018, as well as the third sides 7022, 7024, 7026, 7028, and thefourth sides 7032, 7034, 7036, 7038 as well as the fifth sides 7052,7054, 7056, 7058 may all be oriented at the same acute side angle SArelative to the planar non-forming surface 6040′. The first sides 7002,7004, 7006, 7008 and the second sides 7012, 7014, 7016, 7018 as well asthe third sides 7022, 7024, 7026, 7028, and the fourth sides 7032, 7034,7036, 7038 as well as the fifth sides 7052, 7054, 7056, 7058 may beoriented at different acute angles or combinations of different acuteangles SA and SA′ (FIG. 49) relative to the planar non-forming surface6040′.

In various circumstances, the anvil protrusions may be formed on thestaple-forming under surface so as to protrude upward from the planarsections thereof to form a plurality of staple-guiding surfaces thatcorrespond with the staple-forming pockets to guide the legs ofcorresponding staples therein which may ultimately lead to better formedand more consistently properly formed staples. Such anvil protrusionsprotrude above the anvil forming pockets and angle toward the perimetersthereof so that when contacted by the end of an errant staple leg duringthe stapling process, the anvil protrusion will urge or encourage theerrant staple leg into the proper cup portion of the staple-formingpocket so as to be properly formed. Such anvil protrusions may be formedwith one or more angled surface strategically positioned adjacent atleast a portion of a corresponding staple-forming pocket. The anvilprotrusion may have multiple angled surfaces, wherein the surfacescorrespond to one or more staple-forming pockets in the anvil. The anvilprotrusions may be formed from the same material comprising thestaple-forming undersurface. The various surfaces of the anvilprotrusions may be treated to reduce friction when contacted by staplelegs (e.g., coated with friction reducing coating, polished, etc.).

The entire staple-forming under surface or a large portion of thestaple-forming undersurface may be covered with anvil protrusions sizedand designed to enhance and guide the staple legs of staples intocorresponding portions of the staple-forming pockets. A plurality ofanvil protrusions may be employed. The anvil protrusions may beidentical in size and shape or they may be different in sizes andshapes. The anvil protrusions may be sized and shaped to completely fillin the portions of the anvil forming surface between the staple-formingpockets or to fill in a majority of such spaces. The various anvilprotrusions may be sized and shaped to correspond to a variety ofdifferent staple-forming pocket shapes and configurations, many of whichare disclosed herein as well as in the various references incorporatedherein in their respective entireties. The anvil protrusion arrangementsdisclosed herein may be used with staple-forming pockets arranged inherringbone configurations as well as conventional non-herringbonearrangements.

The various anvil protrusions arrangements and configurations disclosedherein may also be effectively used in connection with anvilarrangements that employ “stepped” staple-forming undersurfaces. Such“stepped” anvil arrangements are used in connection with staplecartridges that have “stepped” decks. A stepped anvil may have twoforming surfaces that are not located on a common plane. The anvilprotrusions disclosed herein is distinguishable from a stepped deckarrangement, as the anvil protrusions extend above the deck surfaceitself and angle toward a corresponding portion of a perimeter of acorresponding staple-forming pocket. As used in this context, the term“angle” means an acute angle that is less than 90 degrees extending fromthe planar non-forming surface. Other anvil projection arrangements, mayemploy radiused surfaces instead of planar angled surfaces to help guidestaple legs into the adjacent forming pockets. Such anvil projectionsmay also improve the stability of the tissue that is clamped between theanvil and staple cartridge and ultimately stapled and cut.

The various anvils described herein that include the anvil protrusionsand tissue stabilization features may be used in connection withsurgical staple cartridges that have atraumatic extenders on the decksurfaces thereof, such as cartridge 4000 described above, for example.In such instances, the anvil protrusions may be aligned or substantiallyaligned or approximately aligned with a corresponding atraumaticextender or extenders on the cartridge. In other anvil arrangements, theanvil protrusions may be oriented so as to avoid alignment or directalignment with the atraumatic extenders on the staple cartridge. Instill other arrangements, the anvils may be used in connection withstaple cartridges that do not have atraumatic extenders, for example.

FIG. 50 illustrates a portion of an anvil 7100 that may be otherwiseidentical to anvil 6000, except for the different arrangement ofstaple-forming pockets 7160, for example. Similar to the anvil 6000, thepockets 7160 are arranged in a herringbone arrangement along thestaple-forming undersurface 7130 of the anvil 7100. The anvil 7100includes a staple-forming undersurface 7130 and a longitudinal slot7126. The longitudinal slot 7126 extends along the longitudinal axis LAof the anvil 7100. In certain instances, a firing element and/or acutting element can translate through the longitudinal slot 7126 duringat least a portion of a firing stroke. The staple-forming pockets 7160are defined in the staple-forming undersurface 7130. The staple-formingundersurface 7130 also includes a non-forming portion 7140 that extendsaround the pockets 7160. The non-forming portion 7140 extends entirelyaround each pocket 7160. In other words, the non-forming portion 7140surrounds the staple-forming pockets 7160. In other instances, at leasta portion of two or more adjacent pockets 7160 can be in abuttingcontact such that a non-forming portion 7140 is not positionedtherebetween.

The forming ratio of the staple-forming undersurface 7130 can beoptimized. By optimizing the forming ratio, more staples can be formedand/or formed to their desired configurations. In certain instances, thesurface area of the non-forming portion 7140 of the anvil 7100 can beminimized with respect to the staple-forming pockets 7160. Additionallyor alternatively, the footprint of the staple-forming pockets 7160 canbe extended or enlarged to maximize the portion of the staple-formingundersurface 7130 that is designed to catch and form the staples.

The pockets 7160 depicted in FIG. 50 are arranged in an inner row 7150a, an intermediate row 7150 b, and an outer row 7150 c on a first sideof the longitudinal slot 7126. Inner pockets 7160 a are positioned inthe inner row 7150 a, intermediate pockets 7160 b are positioned in theintermediate row 7150 b, and outer pockets 7160 c are positioned in theouter row 7150 c. Although not shown in FIG. 50, in at least oneinstance, the pockets 7160 on the opposing side of the slot 7126 canform a mirror image reflection of the pockets 7160 on the first side ofthe longitudinal slot 7126. In other instances, the arrangement ofpockets 7160 in the staple-forming undersurface 7130 can be asymmetricalrelative to the slot 7126 and, in certain instances, the anvil 7100 maynot include the longitudinal slot 7126. In various instances, thepockets 7160 can be arranged in less than or more than three rows oneach side of the slot 7126.

The inner pockets 7160 a are identical, the intermediate pockets 7160 bare identical, and the outer pockets 7160 c are identical; however, theinner pockets 7160 a may be slightly different than the intermediatepockets 7160 b and the outer pockets 7160 c, and the intermediatepockets 7160 b may be slightly different than the outer pockets 7160 c.In other words, the pockets 7160 in each row 7150 a, 7150 b, and 7150 cmay be slightly different or they may be the same or for the purposes ofexplanation, substantially the same. In other instances, the pockets7160 in two or more of the rows can be the same. For example, the innerpockets 7160 a can be the same as the outer pockets 7160 c. Extendedlanding zones 7170 and 7172 of the pockets 7160 a, 7160 b, and 7160 c,which are described herein, can contribute to the different geometriesthereof. Moreover, the shape and size of the extended landing zones 7170and 7172 are confined by the perimeter 7161 of the adjacent, nestedpockets 7160. The landing zones 7170 and 7172 define a polygonal profileand include linear and contoured portions.

The pockets 7160 can be configured to form staples to the same, orsubstantially the same, formed shape. In other instances, the pockets7160 can be configured to form staples to different formed shapes, suchas to different heights and/or configurations. In certain instances, thepockets 7160 can vary longitudinally within each row 7150 a, 7150 b, and7150 c. For example, in certain instances, the depth of the pockets 7160or portions thereof can vary along the length of the anvil 7100 toaccommodate for variations in gap distance between the anvil and thestaple cartridge along the length of an end effector and/or tissue flow,as described herein.

Still referring to FIG. 50, pocket 7160 a has a first end, or proximalend, 7165 a and a second end, or distal end, 7167 a. A first pocket axisFPA extends between the proximal end 7165 a and the distal end 7167 a ofthe pocket 7160 a. The pocket 7160 a includes a perimeter 7161, whichdefines the boundary of the pocket 7160 a. The perimeter 7161 includeslinear portions and contoured portions. More specifically, the perimeter7161 includes linear portions and contoured corners therebetween atwhich the linear portions change directions. In at least somearrangements, at least a portion of the perimeter 7161 of each pocket7160 closely tracks or parallels at least a portion of the perimeter ofone or more adjacent pockets 7160. The rounded perimeter 7161 of thepocket 7160 a can provide a smoother profile, which can be easier tocoin and/or stamp in the staple-forming undersurface 7130 than pocketshaving sharp corners, for example.

The pocket 7160 a includes a proximal cup 7166 a, a distal cup 7168 a,and a neck portion 7169 extending between the proximal cup 7166 a andthe distal cup 7168 a. When a staple is driven into forming contact withthe staple-forming undersurface 7130, the proximal cup 7166 a is alignedwith a proximal staple leg, and the distal cup 7168 a is aligned with adistal staple leg. The cups 7166 a, 7168 a are configured to direct orfunnel the staple legs toward the pocket axis and the central portion ofthe pocket 7160 a, such as the neck portion 7169 a, and to deform thestaple legs into the formed configuration. Each cup 7166 a, 7168 a ofthe pocket 7160 a defines an entrance ramp 7180 and an exit ramp 7182.When forming a staple, the tip of a staple leg can enter the respectivecup 7166 a, 7168 a along the entrance ramp 7180 and exit the respectivecup 7166 a, 7168 a along the exit ramp 7182. At an apex between theentrance ramp 7180 and the exit ramp 7182, the tips of the staple legsare deformed toward the staple base to assume the formed configuration,such as a B-form or modified B-form, for example. The pocket 7160 a alsodefines a bridge 7186 in the neck portion 7169 a between the proximalcup 7166 a and the distal cup 7168 a. The bridge 7186 may be offset fromthe non-forming portion 7140. More specifically, the bridge 7186 may bepositioned below or recessed relative to the non-forming portion 7140.Pockets 7160 b and 7160 c may be formed with the same configurations andcharacteristics as described herein with respect to pocket 7160 a. Sucharrangement results in a reduction of the non-forming portions 7140 ofthe staple-forming undersurface 7130 and facilitates a nesting of therespective lines of pockets. Pockets 7160 a-c are arranged in aherringbone pattern to thereby form a flexible staple line as describedherein. In particular, each pocket 7160 b lines along a correspondingsecond pocket axis SPA that is transverse to the longitudinal axis LA aswell as to the first pocket axis FPA of the adjacent first pockets 7160a. Each third pocket 7160 c lies along a corresponding third pocket axisTPA that is transverse to the longitudinal axis LA. In at least onearrangement, the third pocket axes TPA are parallel to the first pocketaxes FPA and transverse to the second pocket axes SPA.

FIG. 51 illustrates a portion of an anvil 7200 that may be otherwiseidentical to anvil 6000, except for the different arrangement ofstaple-forming pockets 7260, for example. Similar to the anvil 6000, thepockets 7260 are arranged in a herringbone arrangement along thestaple-forming undersurface 7230 of the anvil 7200. The anvil 7200includes a staple-forming undersurface 7230 and a longitudinal slot7226. The longitudinal slot 7226 extends along the longitudinal axis LAof the anvil 7200. In certain instances, a firing element and/or acutting element can translate through the longitudinal slot 7226 duringat least a portion of a firing stroke. The staple-forming pockets 7260are defined in the staple-forming undersurface 7230. The staple-formingundersurface 7230 also includes a non-forming portion 7240 that extendsaround the pockets 7260. The non-forming portion 7240 extends entirelyaround each pocket 7260. In other words, the non-forming portion 7240surrounds the staple-forming pockets 7260. In other instances, at leasta portion of two or more adjacent pockets 7260 can be in abuttingcontact such that a non-forming portion 7240 is not positionedtherebetween.

The forming ratio of the staple-forming undersurface 7230 can beoptimized. By optimizing the forming ratio, more staples can be formedand/or formed to their desired configurations. In certain instances, thesurface area of the non-forming portion 7240 of the anvil 7200 can beminimized with respect to the staple-forming pockets 7260. Additionallyor alternatively, the footprint of the staple-forming pockets 7260 canbe extended or enlarged to maximize the portion of the staple-formingundersurface 7230 that is designed to catch and form the staples.

The pockets 7260 depicted in FIG. 51 are arranged in an inner row 7250a, an intermediate row 7250 b, and an outer row 7250 c on a first sideof the longitudinal slot 7226. Inner pockets 7260 a are positioned inthe inner row 7250 a, intermediate pockets 7260 b are positioned in theintermediate row 7250 b, and outer pockets 7260 c are positioned in theouter row 7250 c. Although not shown in FIG. 51, in at least oneinstance, the pockets 7260 on the opposing side of the slot 7226 canform a mirror image reflection of the pockets 7260 on the first side ofthe longitudinal slot 7226. In other instances, the arrangement ofpockets 7260 in the staple-forming undersurface 7230 can be asymmetricalrelative to the slot 7226 and, in certain instances, the anvil 7200 maynot include the longitudinal slot 7226. In various instances, thepockets 7260 can be arranged in less than or more than three rows oneach side of the slot 7226.

The inner pockets 7260 a are identical, the intermediate pockets 7260 bare identical, and the outer pockets 7260 c are identical; however, theinner pockets 7260 a may be different than the intermediate pockets 7260b and the outer pockets 7260 c, and the intermediate pockets 7260 b maybe different than the outer pockets 7260 c. In other words, the pockets7260 in each row 7250 a, 7250 b, and 7250 c may be different. In otherinstances, the pockets 7260 in two or more of the rows can be the same.For example, the inner pockets 7260 a can be the same as the outerpockets 7260 c. Extended landing zones 7270 and 7272 of the pockets 7260a, 7260 b, and 7260 c, which are described herein, can contribute to thedifferent geometries thereof. Moreover, the shape and size of theextended landing zones 7270 and 7272 are confined by the perimeter 7261of the adjacent, nested pockets 7260. The landing zones 7270 and 7272define a polygonal profile and include linear and contoured portions.

The pockets 7260 can be configured to form staples to the same, orsubstantially the same, formed shape. In other instances, the pockets7260 can be configured to form staples to different formed shapes, suchas to different heights and/or configurations. In certain instances, thepockets 7260 can vary longitudinally within each row 7250 a, 7250 b, and7250 c. For example, in certain instances, the depth of the pockets 7260or portions thereof can vary along the length of the anvil 7200 toaccommodate for variations in gap distance between the anvil and thestaple cartridge along the length of an end effector and/or tissue flow,as described herein.

Still referring to FIG. 51, pocket 7260 a has a first end, or proximalend 7265 a and a second end, or distal end, 7267 a. A first pocket axisFPA extends between the proximal end 7265 a and the distal end 7267 a ofthe pocket 7260 a. The pocket 7260 a includes a perimeter 7261, whichdefines the boundary of the pocket 7260 a. The perimeter 7261 includeslinear portions and contoured portions. More specifically, the perimeter7261 includes linear portions and contoured corners therebetween atwhich the linear portions change directions. In at least somearrangements, at least a portion of the perimeter 7261 of each pocket7260 closely tracks or parallels at least a portion of the perimeter ofone or more adjacent pockets 7260. The rounded perimeter 7261 of thepocket 7260 a can provide a smoother profile, which can be easier tocoin and/or stamp in the staple-forming undersurface 7230 than pocketshaving sharp corners, for example.

The pocket 7260 a includes a proximal cup 7266 a, a distal cup 7268 a,and a neck portion 7269 extending between the proximal cup 7266 a andthe distal cup 7268 a. When a staple is driven into forming contact withthe staple-forming undersurface 7230, the proximal cup 7266 a is alignedwith a proximal staple leg, and the distal cup 7268 a is aligned with adistal staple leg. The cups 7266 a, 7268 a are configured to direct orfunnel the staple legs toward the first pocket axis FPA and the centralportion of the pocket 7260 a, such as the neck portion 7269 a, and todeform the staple legs into the formed configuration. Each cup 7266 a,7268 a of the pocket 7260 a defines an entrance ramp 7280 and an exitramp 7282. When forming a staple, the tip of a staple leg can enter therespective cup 7266 a, 7268 a along the entrance ramp 7280 and exit therespective cup 7266 a, 7268 a along the exit ramp 7282. At an apexbetween the entrance ramp 7280 and the exit ramp 7282, the tips of thestaple legs are deformed toward the staple base to assume the formedconfiguration, such as a B-form or modified B-form, for example. Thepocket 7260 a also defines a bridge 7286 in the neck portion 7269 abetween the proximal cup 7266 a and the distal cup 7268 a. The bridge7286 may be offset from the non-forming portion 7240. More specifically,the bridge 7286 may be positioned below or recessed relative to thenon-forming portion 7240. Pockets 7260 b and 7260 c may be formed withthe same configurations and characteristics as described herein withrespect to pocket 7260 a. Such arrangement results in a reduction of thenon-forming portions 7240 of the staple-forming undersurface 7230 andfacilitates a nesting of the respective lines of pockets. Pockets 7260a-c are arranged in a herringbone pattern to thereby form a flexiblestaple line as described herein. In particular, each pocket 7260 b liesalong a corresponding second pocket axis SPA that is transverse to thelongitudinal axis LA as well as to the first pocket axis FPA of theadjacent first pockets 7260 a. Each third pocket 7260 c lies along acorresponding third pocket axis TPA that is transverse to thelongitudinal axis LA. In at least one arrangement, the third pocket axesTPA are parallel to the first pocket axes FPA and transverse to thesecond pocket axes SPA.

Referring now to FIG. 52, staple-forming pockets 7360 in a portion of ananvil 7300 are depicted. The anvil 7300 includes a staple-formingundersurface 7330 and a longitudinal slot 7326. The longitudinal slot7326 extends along the longitudinal axis LA of the anvil 7300. Incertain instances, a firing element and/or cutting element can translatethrough the longitudinal slot 7326 during at least a portion of a firingstroke. The staple-forming pockets 7360 are defined in thestaple-forming undersurface 7360. The staple-forming undersurface 7330also includes a non-forming portion 7340 that extends around the pockets7360. The non-forming portion 7340 extends entirely around each pocket7360 in FIG. 52. In other words, the non-forming portion 7340 surroundsthe staple-forming pockets 7360. In other instances, at least a portionof two or more adjacent pockets 7360 can be in abutting contact suchthat a non-forming portion 7340 is not positioned therebetween.

The forming ratio of the staple-forming undersurface 7330 can beoptimized. By optimizing the forming ratio, more staples can be formedand/or formed to their desired configurations. In certain instances, thesurface area of the non-forming portion 7340 of the anvil 7300 can beminimized with respect to the staple-forming pockets 7360. Additionallyor alternatively, the footprint of the staple-forming pockets 7360 canbe extended or enlarged to maximize the portion of the staple-formingundersurface 7340 that is designed to catch and form the staples.

The pockets 7360 depicted in FIG. 52 are arranged in three rows 7350 a,7350 b, 7350 c on a first side of the longitudinal slot 7326. The firstrow 7350 a is an inner row, the second row 7350 b is an intermediaterow, and the third row 7350 c is an outer row. Inner pockets 7360 arepositioned in the inner row 7350 a, intermediate pockets 7360 arepositioned in the intermediate row 7350 b, and outer pockets 7360 arepositioned in the outer row 7350 c. Similar to the anvil 7200, thepockets 7360 are arranged in a herringbone arrangement along thestaple-forming undersurface 7330 of the anvil 7300. Although not shownin FIG. 52, in at least one instance, the pockets 7360 on the opposingside of the slot 7326 can form a mirror image reflection of the pockets7360 on the first side of the longitudinal slot 7326. In otherinstances, the arrangement of pockets 7360 in the staple-formingundersurface 7330 can be asymmetrical relative to the slot 7326 and, incertain instances, the anvil 7300 may not include the longitudinal slot7326. In various instances, the pockets 7360 can be arranged in lessthan or more than three rows on each side of the slot 7326.

The pockets 7360 depicted in FIG. 52 are identical to each other. Eachpocket 7360 defined in the staple-forming undersurface 7330 has the samegeometry. In other instances, the geometry of the pockets 7360 can varyrow-to-row and/or longitudinally along the length of the anvil 7300. Forexample, in certain instances, the depth of the pockets 7360 or portionsthereof can vary along the length of the anvil 7300 to accommodate forvariations in gap distance between the anvil and the staple cartridgealong the length of an end effector and/or tissue flow, as describedherein. In at least one arrangement, a pocket 7360 has a first end, orproximal end, 7365 and a second end, or distal end, 7367. A first pocketaxis FPA extends between the proximal end 7365 and the distal end 7367in each of the pockets 7360 in the first line 7350 a. The pocket 7360includes a perimeter 7361, which defines the boundary of the pocket7360. The pocket 7360 also includes a proximal cup 7366, a distal cup7368, and a neck portion 7369 connecting the proximal cup 7366 and thedistal cup 7368. When a staple is driven into forming contact with thestaple-forming undersurface 7303, the proximal cup 7366 is aligned witha proximal staple leg, and the distal cup 7368 is aligned with a distalstaple leg. The cups 7366 and 7368 are configured to direct or funnelthe staple legs toward the corresponding pocket axis and a centralportion of the pocket 7360, such as the neck portion 7369, and to deformthe staple legs into the formed configuration.

Still referring to FIG. 52, each cup 7366, 7368 of the pocket 7360defines an entrance ramp 7370 and an exit ramp 7372. The exit ramp 7372may be steeper than the entrance ramp 7330. When forming a staple, thetip of a staple leg can enter the respective cup 7366, 7368 along theentrance ramp 7370 and exit the respective cup 7366, 7368 along the exitramp 7332. At an apex area or parting line 7374 between the entranceramp 7370 and the exit ramp 7372, the tips of the staple legs aredeformed toward the staple base to assume the formed configuration, suchas a B-form or modified B-form, for example. The pocket 7360 alsodefines a bridge 7376 in the neck portion 7369 between the proximal cup7366 and the distal cup 7368. The bridge 7376 may be offset from thenon-forming portion 7340 of the staple-forming undersurface 7330. Morespecifically, the bridge 7376 may be positioned below or recessedrelative to the non-forming portion 7340.

In at least one example, a pocket 7360 includes sidewalls 7377. In atleast one arrangement, the sidewalls 7377 narrow linearly from the outerends of each cup 7366, 7368 toward the neck portion 7369. Consequently,the widest portion of the cups 7366, 7368 may be at the proximal anddistal ends 7365, 7367 of the pocket 7360, respectively. The widenedregion at the proximal and distal ends 7365, 7367 along with the sidewalls 7377 provides an enlarged footprint for receiving the tip of astaple leg. In various instances, the widened portions of the cups 7366and 7368 define extended landing zones for receiving the staple tips. Asthe cups 7366, 7368 narrow toward the neck portion 7369, the cups 7366,7368 are configured to funnel and/or guide the tips of the staple legstoward and/or along the pocket axis into a formed configuration. Thepocket 7360 defines a chamfered edge 7378 along the sides of the pocket7360. The chamfered edge 7378 serves to enlarge the footprint of thepocket 7360 and guide the tips of the staple legs toward the pocketaxis. In the illustrated arrangement, the pocket 7360 is symmetric aboutthe corresponding pocket axis PA. For example, the perimeter 7361 of thepocket 7360 is symmetric about the corresponding pocket axis. Moreover,the pocket 7360 is symmetric about a central axis CA through the neckportion 7369 and perpendicular to the pocket axis. For example, theperimeter 7361 of the pocket 7360 is symmetric about the central axisCA, and the proximal cup 7366 has the same geometry as the distal cup7368. In other instances, the proximal cup 7366 can be different thanthe distal cup 7368. In various circumstances, the width of the neckportion 7369 is less than the width of the cups 7366 and 7368.Consequently, the central portion of the pocket 7360 is narrower thanthe proximal and distal cups 7366 and 7368.

The geometry of the pockets 7360 facilitates the close arrangement ofthe pockets 7360 in the staple-forming undersurface 7330. For example,because the pockets 7360 include a narrowed neck portion 7369 betweentwo enlarged cups 7366 and 7368, the enlarged cups 7366, 7368 of anotherpocket 7360 can be positioned adjacent to the narrowed neck portion7369. Consequently, the surface area of the staple-forming undersurface7330 that is covered by the pockets 7360 can be optimized. For example,the surface area of the staple-forming undersurface 7330 that is coveredby pockets 7360 is maximized. The “forming ratio” is the ratio of thenon-forming portion 7340 to the forming portion, i.e., the pockets 7360.In various instances, the forming ratio can be at least 1:1, forexample.

In certain instances, though the pockets 7360 are positioned in closeproximity to each other, because the neck portion 7369 narrows, there isspace for the non-forming portion 7340 between adjacent pockets 7360.For example, the non-forming portion 7340 can extend between the neckportion 7369 of a pocket 7360 in an inner row 7350 a and the distal cup7368 of an adjacent pocket 7360 in a second intermediate row 7350 b. Thenon-forming portion 7340 between adjacent pockets 7360 can providesufficient spacing between pockets 7360 to strengthen and/or reinforcethe anvil 7300. Pockets 7360 are arranged in a herringbone pattern tothereby form a flexible staple line as described herein. In particular,each pocket 7360 in the first line 7350 a lies along a correspondingfirst pocket axis FPA lies along a corresponding FPA that is transverseto the longitudinal axis LA. Each pocket 7360 in the second row 7350 bof pockets 7360 lies along a corresponding second pocket axis SPA thatis transverse to the longitudinal axis LA as well as to the first pocketaxis FPA of the adjacent pockets 7360 in the first row 7350 a. Eachpocket 7360 in the third row 7350 c of pockets 7360 lies along acorresponding third pocket axis TPA that is transverse to thelongitudinal axis LA. In at least one arrangement, the third pocket axesTPA are parallel to the first pocket axes FPA and transverse to thesecond pocket axes SPA.

Referring now to FIG. 53, staple-forming pockets 7460 in a portion of ananvil 7400 are depicted. The anvil 7400 includes a staple-formingundersurface 7430 and a longitudinal slot 7426. The longitudinal slot7426 extends along the longitudinal axis LA of the anvil 7400. Incertain instances, a firing element and/or cutting element can translatethrough the longitudinal slot 7426 during at least a portion of a firingstroke. The staple-forming pockets 7460 are defined in thestaple-forming undersurface 7430. The staple-forming undersurface 7430also includes a non-forming portion 7440 that extends around the pockets7460. The non-forming portion 7440 extends entirely around each pocket7460. In other words, the non-forming portion 7440 surrounds thestaple-forming pockets 7460. In other instances, at least a portion oftwo or more adjacent pockets 7460 can be in abutting contact such that anon-forming portion 7440 is not positioned therebetween. Additionally,the non-forming portion 7440 extends through each pocket 7460, asdescribed herein.

The forming ratio of the staple-forming undersurface 7430 can beoptimized. By optimizing the forming ratio, more staples can be formedand/or formed to their desired configurations. In certain instances, thesurface area of the non-forming portion 7440 of the anvil 7400 can beminimized with respect to the staple-forming pockets 7460. Additionallyor alternatively, the footprint of the staple-forming pockets 7460 canbe extended or enlarged to maximize the portion of the staple-formingundersurface 7440 that is designed to catch and form the staples.

The pockets 7460 depicted in FIG. 53 are arranged in an inner row 7450a, an intermediate row 7450 b, and an outer row 7450 c on a first sideof the longitudinal slot 7426. Inner pockets 7460 are positioned in theinner row 7450 a, intermediate pockets 7460 are positioned in theintermediate row 7450 b, and outer pockets 7460 are positioned in theouter row 7450 c. The pockets 7460 are arranged in a herringbonearrangement along the staple-forming undersurface 7430 of the anvil7430. Although not shown in FIG. 53, in at least one instance, thepockets 7460 on the opposing side of the slot 7426 can form a mirrorimage reflection of the pockets 7460 on the first side of thelongitudinal slot 7426. In other instances, the arrangement of pockets7460 in the staple-forming undersurface 7430 can be asymmetricalrelative to the slot 7426 and, in certain instances, the anvil 7400 maynot include the longitudinal slot 7426. In various instances, thepockets 7460 can be arranged in less than or more than three rows oneach side of the slot 7426.

The pockets 7460 depicted in FIG. 53 are identical to each other. Eachpocket 7460 defined in the staple-forming undersurface 7430 has the samegeometry. In other instances, the geometry of the pockets 7460 can varyrow-to-row and/or longitudinally along the length of the anvil 7400. Forexample, in certain instances, the depth of the pockets 7460 or portionsthereof can vary along the length of the anvil 7400 to accommodate forvariations in gap distance between the anvil and the staple cartridgealong the length of an end effector and/or tissue flow, as describedherein. In at least one example, a pocket 7460 has a first end, orproximal end, 7465 and a second end, or distal end, 7468. A pocket axisextends between the proximal end 7465 and the distal end 7467 of thepocket 7460. The pocket 7460 includes a perimeter 7461, which definesthe boundary of the pocket 7460. The perimeter 7461 includes roundedcorners at the proximal and distal ends 7465 and 7467 of the pocket7460. The pocket 7460 also includes a proximal cup 7466 and a distal cup7468. A portion of the non-forming portion 7440 extends between theproximal cup 7466 and the distal cup 7468. In other words, the pocket7460 includes two separate and discrete cups 7466 and 7468 in thestaple-forming undersurface 7430. When a staple is driven into formingcontact with the staple-forming undersurface 7430, the proximal cup 7466is aligned with a proximal staple leg, and the distal cup 7468 isaligned with a distal staple leg. The cups 7466, 7468 are configured todirect or funnel the staple legs toward the pocket axis and a centralportion of the pocket 7460 and to deform the staple legs into the formedconfiguration.

Referring primarily to FIG. 53, each cup 7466, 7468 of the pocket 7460defines an entrance ramp 7480 and an exit ramp 7482. The exit ramp 7482is steeper than the entrance ramp 7480. When forming a staple, the tipof a staple leg can enter the respective cup 7466, 7468 along theentrance ramp 7480 and exit the respective cup 7466, 7468 along the exitramp 7482. At an apex 7484 between the entrance ramp 7480 and the exitramp 7482, the tips of the staple legs are deformed toward the staplebase to assume the formed configuration, such as a B-form or modifiedB-form, for example. The pocket 7460 also defines a bridge 7486 betweenthe proximal cup 7466 and the distal cup 7468. The bridge 7486 isaligned with the non-forming portion 7440. More specifically, the bridge7486 is a planar extension of the non-forming portion 7440, whichextends between the proximal and distal cups 7466, 7468.

In the illustrated example, each pocket 7460 includes a pair ofsidewalls 7478 that are oriented at an angle relative to the non-formingportion 7440. The angular orientation of the sidewalls 7478 may beconstant along the length of each of the cups 7466, 7468. The distancebetween the sidewalls 7478 narrows between the outer ends of each cup7466, 7468 and inner ends of the cups 7466, 7468. For example, thesidewalls 7478 extend along an inward contour to define a contour in theperimeter 7461 of the pocket 7460. The widest portion of the cups 7466,7468 is at the proximal and distal ends of the pocket 7460. The widenedregion provides an enlarged footprint for receiving the tip of a stapleleg. As the cups 7466, 7468 narrow toward the bridge 7486, the sidewalls7478 are configured to funnel and/or guide the tips of the staple legstoward and/or along the pocket axis and into a formed configuration.

In the illustrated arrangement, the pockets 7460 located in the first orinner row 7450 a of pockets 7460 lie along a first pocket axis FPA thatis transverse to the longitudinal axis LA. Each of the pockets 7460 inthe second or intermediate row 7450 b of pockets 7460 lie along a secondpocket axis SPA that is transverse to the longitudinal axis LA as wellas to the first pocket axes FPA. Each of the pockets in the outer orthird row 7450 c of pockets 7460 lie along a third pocket axis TPA thatis parallel to the first pocket axes FPA in one arrangement or they maynot be parallel to the first pocket axes, but are nonetheless transverseto the longitudinal axis LA. Each pocket 7460 is symmetric about itsrespective pocket axis. For example, the perimeter 7461 of the pocket7460 is symmetric about the pocket axis. Moreover, the pocket 7460 issymmetric about a central axis CA between the proximal and distal cups7466, 7468 and perpendicular to its respective the pocket axis. Forexample, the perimeter 7461 of the pocket 7460 is symmetric about thecentral axis CA, and the proximal cup 74660 has the same geometry as thedistal cup 7468. In other instances, the proximal cup 7466 can bedifferent than the distal cup 7468. U.S. patent application Ser. No.15/385,900, filed Dec. 21, 2016, entitled STAPLE-FORMING POCKETARRANGEMENTS COMPRISING PRIMARY SIDEWALLS AND POCKET SIDEWALLS, now U.S.Patent Application Publication No. 2018/0168601, the entire disclosureof which is hereby incorporated by reference herein discloses otherpocket configurations that may be employed with the various anvilarrangements disclosed herein.

FIGS. 54-57 illustrate other pocket configurations that may be employedwith the various anvil arrangements disclosed herein. Turning to FIG.54, the pocket 7560 includes a first or proximal end 7565 and a secondend or distal end 7567. A pocket axis PA extends between the proximalend 7565 and the distal end 7567. The pocket 7560 includes a perimeter7561, which defines the boundary of the pocket 7560. The pocket 7560also includes a proximal cup 7566, a distal cup 7568, and a neck portion7569 connecting the proximal cup 7566 and the distal cup 7568. Each cup7566, 7568 of the pocket 7560 defines an entrance ramp 7570 and an exitramp 7572. When forming a staple, the tip of a staple leg can enter therespective cup 7566, 7568 along the entrance ramp 7570 and exit therespective cup 7566, 7568 along the exit ramp 7532. At an apex area orparting line 7574 between the entrance ramp 7570 and the exit ramp 7572,the tips of the staple legs are deformed toward the staple base toassume the formed configuration, such as a B-form or modified B-form,for example. In the illustrated example, the pocket 7560 includes acentrally disposed forming groove 7580 that lies along the pocket axisPA and extends from the proximal cup 7566 to the distal cup 7568. Theforming groove 7580 bisects each of the entry and exit ramps 7570, 7572as shown.

The pocket 7560 also defines a bridge 7576 in the neck portion 7569between the proximal cup 7566 and the distal cup 7568. The bridge 7576may be offset from the non-forming portion 7540 of the staple-formingundersurface 7530. More specifically, the bridge 7576 may be positionedbelow or recessed relative to the non-forming portion 7540. In at leastone example, the pocket 7560 includes sidewalls 7577. In at least onearrangement, the distance between the sidewalls 7577 narrows linearlyfrom the outer ends of each cup 7566, 7568 toward the neck portion 7569.Consequently, the widest portion of the cups 7566, 7568 may be at theproximal and distal ends 7565, 7567 of the pocket 7560, respectively.The widened region at the proximal and distal ends 7565, 7567 along withthe sidewalls 7577 provides an enlarged footprint for receiving the tipof a staple leg preferably within the staple-forming groove 7580. Invarious instances, the widened portions of the cups 7566 and 7568 defineextended landing zones for receiving the staple tips. As the cups 7566,7568 narrow toward the neck portion 7369, the cups 7366, 7368 areconfigured to funnel and/or guide the tips of the staple legs towardand/or along the pocket axis into the forming groove 7580 and into aformed configuration. The pocket 7560 defines a chamfered edge 7578along the sides of the pocket 7560. The chamfered edge 7578 serves toenlarge the footprint of the pocket 7560 and guide the tips of thestaple legs toward the pocket axis. In the illustrated arrangement, thepocket 7560 is symmetric about the corresponding pocket axis PA. Forexample, the perimeter 7561 of the pocket 7560 is symmetric about thecorresponding pocket axis. Moreover, the pocket 7560 is symmetric abouta central axis CA through the neck portion 7569 and perpendicular to thepocket axis. For example, the perimeter 7561 of the pocket 7560 issymmetric about the central axis CA, and the proximal cup 7566 has thesame geometry as the distal cup 7568. In other instances, the proximalcup 7566 can be different than the distal cup 7568. In variouscircumstances, the width of the neck portion 7569 is less than the widthof the cups 7566 and 7568. Consequently, the central portion of thepocket 7560 is narrower than the proximal and distal cups 7566 and 7568.In the illustrated arrangement, the proximal cup 7566 has a pointed end7590 and the distal cup 7568 has a pointed end 7592. The forming groove7580 extends from each pointed end 7590, 7592 to enhance the likelihoodthat the tips of the staple leg will fall ingot the forming groove 7580during firing. When a staple is driven into forming contact with thestaple-forming undersurface 7530, the proximal cup 7566 is aligned witha proximal staple leg, and the distal cup 7568 is aligned with a distalstaple leg. The cups 7566 and 7568 are configured to direct or funnelthe staple legs toward the corresponding pocket axis and forming groove7580 and a central portion of the pocket 7560, such as the neck portion7569, and to deform the staple legs into the formed configuration.

Turning to FIG. 55, the pocket 7660 includes a first or proximal end7665 and a second end or distal end 7667. A pocket axis PA extendsbetween the proximal end 7665 and the distal end 7667. The pocket 7660includes a perimeter 7661, which defines the boundary of the pocket7660. The pocket 7660 also includes a proximal cup 7666, a distal cup7668, and a neck portion 7669 connecting the proximal cup 7666 and thedistal cup 7668. In the illustrated example, the pocket 7660 includes acentrally disposed forming groove 7680 that lies along the pocket axisPA and extends from the proximal cup 7666 to the distal cup 7668. Theforming groove 7680 defines an entrance ramp 7670 and an exit ramp 7672.When forming a staple, the tip of a staple leg can enter the respectivecup 7666, 7668 along the entrance ramp 7670 and exit the respective cup7666, 7668 along the exit ramp 7672. At an apex area or parting line7674 between the entrance ramp 7670 and the exit ramp 7672, the tips ofthe staple legs are deformed toward the staple base to assume the formedconfiguration, such as a B-form or modified B-form, for example.

The pocket 7660 also defines a bridge 7676 in the neck portion 7669between the proximal cup 7666 and the distal cup 7668. The bridge 7676may be offset from the non-forming portion 7640 of the staple-formingundersurface 7630. More specifically, the bridge 7676 may be positionedbelow or recessed relative to the non-forming portion 7640. In at leastone example, the pocket 7660 includes sidewalls 7677. In at least onearrangement, the distance between the sidewalls 7677 narrows linearlyfrom the outer ends of each cup 7666, 7668 toward the neck portion 7669.Consequently, the widest portion of the cups 7666, 7668 may be at theproximal and distal ends 7665, 7667 of the pocket 7660, respectively.The widened region at the proximal and distal ends 7665, 7667 along withthe sidewalls 7677 provides an enlarged footprint for receiving the tipof a staple leg preferably within the staple-forming groove 7680. Invarious instances, the widened portions of the cups 7666 and 7568 defineextended landing zones for receiving the staple tips. As the cups 7666,7668 narrow toward the neck portion 7669, the cups 7666, 7668 areconfigured to funnel and/or guide the tips of the staple legs towardand/or along the pocket axis into the forming groove 7680 and into aformed configuration. The pocket 7660 defines a chamfered edge 7678along the sides of the pocket 7660. The chamfered edge 7678 serves toenlarge the footprint of the pocket 7660 and guide the tips of thestaple legs toward the pocket axis PA. In the illustrated arrangement,the pocket 7660 is symmetric about the corresponding pocket axis PA. Forexample, the perimeter 7661 of the pocket 7660 is symmetric about thecorresponding pocket axis. Moreover, the pocket 7660 is symmetric abouta central axis CA through the neck portion 7669 and perpendicular to thepocket axis PA. For example, the perimeter 7661 of the pocket 7660 issymmetric about the central axis CA, and the proximal cup 7666 has thesame geometry as the distal cup 7668. In other instances, the proximalcup 7666 can be different than the distal cup 7668. In variouscircumstances, the width of the neck portion 7669 is less than the widthof the cups 7666 and 7668. Consequently, the central portion of thepocket 7560 is narrower than the proximal and distal cups 7666 and 7668.When a staple is driven into forming contact with the staple-formingundersurface 7630, the proximal cup 7666 is aligned with a proximalstaple leg, and the distal cup 7668 is aligned with a distal staple leg.The cups 7666 and 7668 are configured to direct or funnel the staplelegs toward the corresponding pocket axis and forming groove 7680 and acentral portion of the pocket 7660, such as the neck portion 7669, andto deform the staple legs into the formed configuration.

Turning to FIG. 56, the pocket 7760 includes a first or proximal end7765 and a second end or distal end 7767. A pocket axis PA extendsbetween the proximal end 7765 and the distal end 7767. The pocket 7760includes a perimeter 7761, which defines the boundary of the pocket7760. The pocket 7760 also includes a proximal cup 7766, a distal cup7768, and a neck portion 7769 connecting the proximal cup 7766 and thedistal cup 7768. In the illustrated example, the pocket 7760 includes acentrally disposed forming groove 7780 that lies along the pocket axisPA and extends from the proximal cup 7766 to the distal cup 7768. Theforming groove 7780 defines an entrance ramp 7770 and an exit ramp 7772.When forming a staple, the tip of a staple leg can enter the respectivecup 7766, 7768 along the entrance ramp 7770 and exit the respective cup7766, 7768 along the exit ramp 7772. At an apex area or parting line7774 between the entrance ramp 7770 and the exit ramp 7772, the tips ofthe staple legs are deformed toward the staple base to assume the formedconfiguration, such as a B-form or modified B-form, for example.

The pocket 7760 also defines a bridge 7776 in the neck portion 7769between the proximal cup 7766 and the distal cup 7768. The bridge 7776may be offset from the non-forming portion 7740 of the staple-formingundersurface 7730. More specifically, the bridge 7776 may be positionedbelow or recessed relative to the non-forming portion 7740. In at leastone example, the pocket 7760 includes sidewalls 7777. In at least onearrangement, the distance between the sidewalls 7777 narrows linearlyfrom the outer ends of each cup 7766, 7768 toward the neck portion 7769.Consequently, the widest portion of the cups 7766, 7768 may be at theproximal and distal ends 7765, 7767 of the pocket 7760, respectively.The widened region at the proximal and distal ends 7765, 7767 along withthe sidewalls 7777 provides an enlarged footprint for receiving the tipof a staple leg preferably within the staple-forming groove 7780. Invarious instances, the widened portions of the cups 7766 and 7768 defineextended landing zones for receiving the staple tips. As the cups 7766,7768 narrow toward the neck portion 7769, the cups 7766, 7768 areconfigured to funnel and/or guide the tips of the staple legs towardand/or along the pocket axis into the forming groove 7780 and into aformed configuration. The pocket 7760 defines a chamfered edge 7778along the sides of the pocket 7760. The chamfered edge 7778 serves toenlarge the footprint of the pocket 7760 and guide the tips of thestaple legs toward the pocket axis PA. In the illustrated arrangement,the pocket 7760 is symmetric about the corresponding pocket axis PA. Forexample, the perimeter 7761 of the pocket 7760 is symmetric about thecorresponding pocket axis. Moreover, the pocket 7760 is symmetric abouta central axis CA through the neck portion 7769 and perpendicular to thepocket axis PA. For example, the perimeter 7761 of the pocket 7760 issymmetric about the central axis CA, and the proximal cup 7766 has thesame geometry as the distal cup 7768. In other instances, the proximalcup 7766 can be different than the distal cup 7668. In variouscircumstances, the width of the neck portion 7769 is less than the widthof the cups 7766 and 7768. Consequently, the central portion of thepocket 7560 is narrower than the proximal and distal cups 7766 and 7768.When a staple is driven into forming contact with the staple-formingundersurface 7730, the proximal cup 7766 is aligned with a proximalstaple leg, and the distal cup 7768 is aligned with a distal staple leg.The cups 7666 and 7768 are configured to direct or funnel the staplelegs toward the corresponding pocket axis and forming groove 7780 and acentral portion of the pocket 7760, such as the neck portion 7769, andto deform the staple legs into the formed configuration.

Turning to FIG. 57, the pocket 7860 includes a first or proximal end7865 and a second end or distal end 7867. A pocket axis PA extendsbetween the proximal end 7865 and the distal end 7867. The pocket 7860includes a perimeter 7861, which defines the boundary of the pocket7860. The pocket 7860 also includes a proximal cup 7866, a distal cup7868, and a neck portion 7869 connecting the proximal cup 7866 and thedistal cup 7868. Each of the proximal and distal cups 7866, 7868 definean entrance ramp 7870 and an exit ramp 7872. When forming a staple, thetip of a staple leg can enter the respective cup 7866, 7868 along theentrance ramp 7870 and exit the respective cup 7866, 7868 along the exitramp 7872. At an apex area or parting line 7874 between the entranceramp 7870 and the exit ramp 7872, the tips of the staple legs aredeformed toward the staple base to assume the formed configuration, suchas a B-form or modified B-form, for example.

The pocket 7860 also defines a bridge 7876 in the neck portion 7869between the proximal cup 7866 and the distal cup 7868. The bridge 7876may be offset from the non-forming portion 7840 of the staple-formingundersurface 7830. More specifically, the bridge 7876 may be positionedbelow or recessed relative to the non-forming portion 7840. In at leastone example, the pocket 7860 includes three sidewalls 7877, 7878, 7879.Sidewalls 7877, 7878, 7879 may be angled relative to each other. In atleast one arrangement, the distance between the sidewalls 7878, 7879narrows linearly from the outer ends of each cup 7866, 7868 toward theneck portion 7869. Consequently, the widest portion of the cups 7866,7868 may be at the proximal and distal ends 7865, 7867 of the pocket7860, respectively. The widened region at the proximal and distal ends7865, 7867 along with the sidewalls 7877, 7878, 7879 provides anenlarged footprint for receiving the tip of a staple leg within the cups7866, 7868. In various instances, the widened portions of the cups 7866and 7868 define extended landing zones for receiving the staple tips. Asthe cups 7866, 7868 narrow toward the neck portion 7869, the cups 7866,7868 are configured to funnel and/or guide the tips of the staple legstoward and/or along the pocket axis PA into a formed configuration. Thepocket 7860 defines a chamfered edge 7878 along the sides of the pocket7860. The chamfered edge 7878 serves to enlarge the footprint of thepocket 7860 and guide the tips of the staple legs toward the pocket axisPA. In the illustrated arrangement, the pocket 7860 is symmetric aboutthe corresponding pocket axis PA. For example, the perimeter 7861 of thepocket 7860 is symmetric about the corresponding pocket axis. Moreover,the pocket 7860 is symmetric about a central axis CA through the neckportion 7869 and perpendicular to the pocket axis PA. For example, theperimeter 7861 of the pocket 7860 is symmetric about the central axisCA, and the proximal cup 7866 has the same geometry as the distal cup7868. In other instances, the proximal cup 7866 can be different thanthe distal cup 7868. In various circumstances, the width of the neckportion 7869 is less than the width of the cups 7866 and 7868.Consequently, the central portion of the pocket 7860 is narrower thanthe proximal and distal cups 7866 and 7868. When a staple is driven intoforming contact with the staple-forming undersurface 7730, the proximalcup 7866 is aligned with a proximal staple leg, and the distal cup 7868is aligned with a distal staple leg. The cups 7866 and 7868 areconfigured to direct or funnel the staple legs toward the correspondingpocket axis and forming groove 7880 and a central portion of the pocket7860, such as the neck portion 7869, and to deform the staple legs intothe formed configuration.

FIG. 58 illustrates another form of anvil 8000 that is similar to anvil6000 described above except for the differences discussed herein. Theanvil 8000 includes an anvil body 8010 that defines a staple-formingundersurface generally designated as 8030 through which the elongateslot 8026 passes. The staple-forming undersurface 8030 serves to formledges 8032, 8034 on each side of the slot 8026 within the anvil body8010 for sliding engagement by protrusions formed on or attached to theknife of firing member that passes through the slot 8026 during thestaple firing and tissue cutting processes. The staple-formingundersurface 8030 comprises planar surface portions 8040 that may bereferred to herein as non-forming surface portions on each side of theslot 8026 that each have a plurality of staple-forming pockets 8060formed therein. The anvil 8000 is generally complementary to theparticular staple cartridge supported within the elongate channel. Forexample, the arrangement of staple-forming pockets 8060 in the anvil8000 can correspond to the arrangement of staples and staple cavities inthe staple cartridge supported in the elongate channel. The formingratio of the staple-forming undersurface can be optimized. By optimizingthe forming ratio, more staples can be formed and/or formed to theirdesired configurations. In certain instances, the surface area of thenon-forming portion 8040 of the anvil 8000 can be minimized with respectto the staple-forming pockets 8060. Additionally or alternatively, thefootprint of the staple-forming pockets 8060 can be extended or enlargedto maximize the portion of the staple-forming undersurface 8030 that isdesigned to catch and form the staples.

In the illustrated arrangement, the staple-forming pockets 8060 arearranged in three rows 8050 a, 8050 b, 8050 c on a first side of thelongitudinal slot 8026. The first row 8050 a is an inner row, the secondrow 8050 b is an intermediate row and third row 8050 c is an outer row.Inner pockets 8060 a are positioned in the inner row 8050 a,intermediate pockets 8060 b are positioned in the intermediate row 8050b, and outer pockets 8060 c are positioned in the outer row 8050 c. Thepockets 8060 a-c are arranged in a herringbone arrangement along thestaple-forming undersurface 8030 of the anvil 8000. In at least oneinstance, the pockets 8060 a-c on the opposing side of the slot 8026 canform a mirror image reflection of the pockets 8060 a-c on the first sideof the longitudinal slot 8026. In other instances, the arrangement ofpockets 8060 in the staple-forming undersurface 8030 can be asymmetricalrelative to the slot 8026 and, in certain instances, the anvil 8000 maynot include the longitudinal slot 8026. In various instances, thepockets 8060 can be arranged in less than or more than three rows oneach side of the slot 8026. Pockets 8060 a-c may comprise, for example,pockets 6060 described herein or they may comprise other pocketsincluding any of the other pocket configurations disclosed herein.

In the example depicted in FIG. 58, the anvil 8000 includes a pluralityof tissue stabilization features 8080. In at least one arrangement, eachstabilization feature 8080 comprises a tissue stabilization cavity 8082that is formed in the staple-forming undersurface 8030. Morespecifically, each tissue stabilization cavity 8082 comprises anelongate cavity that is formed in the non-forming surface portions 8040of the anvil 8000. In the illustrated example, there are two lines 8070a, 8070 b of tissue stabilization cavities 8082 on each side of theelongate slot 8026. Each tissue stabilization cavity 8082 has anenclosed bottom 8084 and a vertical side wall or side walls 8086extending therefrom. In one arrangement, the bottom 8084 is planar.However, in other arrangements, the enclosed bottom 8084 may not beplanar. The tissue stabilization cavities 8082 may be as deep as thepockets 8060. The tissue stabilization cavities 8082 may be deeper thanpockets 8060 a-c or they may be shallower than pockets 8060 a-c. Instill other configurations, some of the tissue stabilization cavities8082 may be deeper than pockets 8060 a-c and other tissue stabilizationcavities 8082 may be shallower than pockets 8060 a-c in the same anvil8000. The tissue stabilization cavities 8082 may have the sameperimetrical shape as the pockets 8060 a-c or they may have aperimetrical shape that differs from the perimetrical shape of thepockets 8060 a-c. Each tissue stabilization cavity 8082 may be longerand/or wider than a pocket 8060 a-c or the tissue stabilization cavity8082 may be shorter and/or narrower than a pockets 8060 a-c. The tissuestabilization cavities 8082 may be distinguishable from the pockets 8060a-c in that the tissue stabilization cavities have an enclosed bottom8084. While the tissue stabilization cavities 8082 may be designed toreceive adjacent tissue therein during the clamping and staplingprocess, the enclosed bottom 8084 and smooth interior wall or walls 8086prevent the tissue from becoming hung up and or trapped which could leadto tissue damage when the tissue is removed from the end effector.

In the example illustrated in FIG. 58, each tissue stabilization cavity8082 lies along a stabilization axis SA. The stabilization axes SA aretransverse to the first pocket axes FPA, the second pocket axes SPA andthe third pocket axes TPA. The stabilization axes of the tissuestabilization cavities 8082 in the first or inner row 8079 a of tissuestabilization cavities 8082 are parallel to the stabilization axes ofthe tissue stabilization cavities 8082 in the outer or second row 8079 bof tissue stabilization cavities 8082. Each of the stabilization axes SAis transverse to the longitudinal axis LA. During the stapling process,when the anvil 8000 gets pivoted onto the target tissue to clamp thetarget tissue between the staple-forming under surface 8030 of the anvil8000 and the staple cartridge in the end effector, correspondingportions of the target tissue may enter the tissue stabilizationcavities 8082 which will help to minimize shifting or rolling of thetarget tissue as the knife or firing member is advanced through theanvil 8000. The angled orientation of the tissue stabilization cavities8082 relative to the direction of the knife (along the longitudinal axisLA) may serve to further stabilize the tissue during cutting. Inaddition, because some of the target tissue is able to enter thestabilization cavities, the anvil 8000 may be able to assume a closerposition relative to the cartridge during firing and thereby reduce anamount of bending stress normally experienced by the anvil. Suchadvantage may also result in lower closure and firing forces beingneeded during the closing and firing processes.

FIG. 59 illustrates another form of anvil 8100 that is similar to anvil8000 described above except for the differences discussed herein. Theanvil 8100 includes an anvil body 8110 that defines a staple-formingundersurface generally designated as 8130 through which the elongateslot 8126 passes. The staple-forming undersurface 8130 comprises planarsurface portions 8140 that may be referred to herein as non-formingsurface portions on each side of the slot 8126 that each have aplurality of staple-forming pockets 8060 formed therein. The anvil 8100is generally complementary to the particular staple cartridge supportedwithin the elongate channel. For example, the arrangement ofstaple-forming pockets 8060 in the anvil 8100 can correspond to thearrangement of staples and staple cavities in the staple cartridgesupported in the elongate channel. The forming ratio of thestaple-forming undersurface can be optimized. By optimizing the formingratio, more staples can be formed and/or formed to their desiredconfigurations. In certain instances, the surface area of thenon-forming portion 8140 of the anvil 8100 can be minimized with respectto the staple-forming pockets 8060. Additionally or alternatively, thefootprint of the staple-forming pockets 8060 can be extended or enlargedto maximize the portion of the staple-forming undersurface 8130 that isdesigned to catch and form the staples.

In the illustrated arrangement, the staple-forming pockets 8060 arearranged in three rows 8050 a, 8050 b, 8050 c on a first side of thelongitudinal slot 8126. The first row 8050 a is an inner row, the secondrow 8050 b is an intermediate row and third row 8050 c is an outer row.Inner pockets 8060 a are positioned in the inner row 8050 a,intermediate pockets 8060 b are positioned in the intermediate row 8050b, and outer pockets 8060 c are positioned in the outer row 8050 c. Thepockets 8060 a-c are arranged in a herringbone arrangement along thestaple-forming undersurface 8130 of the anvil 8100. In at least oneinstance, the pockets 8060 a-c on the opposing side of the slot 8026 canform a mirror image reflection of the pockets 8060 a-c on the first sideof the longitudinal slot 8126. In other instances, the arrangement ofpockets 8060 in the staple-forming undersurface 8130 can be asymmetricalrelative to the slot 8026 and, in certain instances, the anvil 8100 maynot include the longitudinal slot 8126. In various instances, thepockets 8060 can be arranged in less than or more than three rows oneach side of the slot 8026. Pockets 8060 a-c may comprise, for example,pockets 6060 described herein or they may comprise other pocketsincluding any of the other pocket configurations disclosed herein. Eachfirst pocket 8060 a lies along a corresponding first pocket axis FPAthat is transverse to the longitudinal axis LA. Each second pocket 8060ba lies along a corresponding second pocket axis SPA that is transverseto the longitudinal axis LA as well as the first pocket axes FPA. Eachthird pocket 8060 c lies along a corresponding third pocket axis TPAthat is transverse to the longitudinal axis LA as well as to the secondpocket axes SPA. The third pocket axes TPA may be parallel with thefirst pocket axes FPA.

In the example depicted in FIG. 59, the anvil 8100 includes a pluralityof tissue stabilization features 8180 that are arranged in four rows8170 a, 8170 b, 8170 c, 8170 d on a first side of the longitudinal slot8126. The first row 8170 a is an inner row and includes a plurality oftissue stabilization cavities 8182 a therein that are each arranged on acorresponding first stabilization axis FSA that is transverse to thelongitudinal axis LA. Each first stabilization axis FSA may be parallelto the first pocket axes FPA. The second row 8170 b is an intermediaterow and includes a plurality of tissue stabilization cavities 8182 btherein that are each arranged on a corresponding second stabilizationaxis SSA that is transverse to the longitudinal axis LA as well as tothe first stabilization axes FSA. Each second stabilization axis SSA maybe parallel to the second pocket axes SPA. The third row 8170 c isanother intermediate row and includes a plurality of tissuestabilization cavities 8182 c therein that are each arranged on acorresponding third stabilization axis TSA that is transverse to thelongitudinal axis LA as well as to the first stabilization axes FSA.Each second stabilization axis SSA may be parallel to the secondstabilization axes SSA as well as to the second pocket axes SPA. Thefourth row 8170 d is an outer row and includes a plurality of tissuestabilization cavities 8182 d therein that are each arranged on acorresponding fourth stabilization axis FRSA that is parallel to thelongitudinal axis LA. Each fourth stabilization cavity 8182 d may beoriented along the corresponding outer edge 8112 of the anvil body 8110as shown in FIG. 59, for example.

In certain instances, each tissue stabilization cavity 8182 a-d has anenclosed bottom 8184 and vertical side walls 8186 extending therefrom.In one arrangement, the bottom 8184 is planar. However, in otherarrangements, the enclosed bottom 8184 may not be planar. The tissuestabilization cavities 8182 a-d may be as deep as the pockets 8060 a-c.The tissue stabilization cavities 8182 a-d may be deeper than pockets8060 a-c or they may be shallower than pockets 8060 a-c. In still otherconfigurations, some of the tissue stabilization cavities 8182 a-d maybe deeper than pockets 8060 a-c and other tissue stabilization cavities8182 a-d may be shallower than pockets 8060 a-c in the same anvil 8100.The tissue stabilization cavities 8182 a-d may have the sameperimetrical shape as the pockets 8060 a-c or they may have aperimetrical shape that differs from the perimetrical shape of thepockets 8060 a-c. Each tissue stabilization cavity 8082 may be longerand/or wider than a pocket 8060 a-c or the tissue stabilization cavity8182 a-d may be shorter and/or narrower than a pockets 8060 a-c. Thetissue stabilization cavities 8182 a-d may be distinguishable from thepockets 8060 a-c in that the tissue stabilization cavities 8182 a-d havean enclosed bottom 8184. While the tissue stabilization cavities 8182a-d may be designed to receive adjacent tissue therein during theclamping and stapling process, the enclosed bottom 8184 and smoothinterior wall or walls 8186 prevent the tissue from becoming hung up andor trapped which could lead to tissue damage when the tissue is removedfrom the end effector. Each of the first second and third stabilizationaxes FSA, SSA, TSA is transverse to the longitudinal axis LA. During thestapling process, when the anvil 8100 gets pivoted closed onto thetarget tissue to clamp the target tissue between the staple-formingunder surface 8130 of the anvil 8100 and the staple cartridge in the endeffector, corresponding portions of the target tissue will enter thetissue stabilization cavities 8182 a-c which will help to minimizeshifting or rolling of the target tissue as the knife or firing memberis advanced through the anvil 8100. The angled orientation of the tissuestabilization cavities 8182 a-c relative to the direction of the knife(along the longitudinal axis LA) may serve to further stabilize thetissue during cutting. In addition, because some of the target tissue isable to enter the stabilization cavities, the anvil 8100 may be able toassume a closer position relative to the cartridge during firing andthereby reduce an amount of bending stress normally experienced by theanvil. Such advantage may also result in lower closure and firing forcesbeing needed during the closing and firing processes.

FIG. 60 illustrates another form of anvil 8200 that is similar to anvil8000 described above except for the differences discussed herein. Theanvil 8200 includes an anvil body 8210 that defines a staple-formingundersurface generally designated as 8230 through which an elongate slot8226 passes. The staple-forming undersurface 8230 comprises planarsurface portions 8240 that may be referred to herein as non-formingsurface portions on each side of the slot 8226 that each have aplurality of staple-forming pockets 8060 formed therein. The anvil 8200is generally complementary to the particular staple cartridge supportedwithin the elongate channel. For example, the arrangement ofstaple-forming pockets 8060 in the anvil 8200 can correspond to thearrangement of staples and staple cavities in the staple cartridgesupported in the elongate channel. The forming ratio of thestaple-forming undersurface can be optimized. By optimizing the formingratio, more staples can be formed and/or formed to their desiredconfigurations. In certain instances, the surface area of thenon-forming portion 8240 of the anvil 8200 can be minimized with respectto the staple-forming pockets 8060. Additionally or alternatively, thefootprint of the staple-forming pockets 8060 can be extended or enlargedto maximize the portion of the staple-forming undersurface 8230 that isdesigned to catch and form the staples.

In the illustrated arrangement, the staple-forming pockets 8060 arearranged in three rows 8050 a, 8050 b, 8050 c on a first side of thelongitudinal slot 8226. The first row 8050 a is an inner row, the secondrow 8050 b is an intermediate row and third row 8050 c is an outer row.Inner pockets 8060 a are positioned in the inner row 8050 a,intermediate pockets 8060 b are positioned in the intermediate row 8050b, and outer pockets 8060 c are positioned in the outer row 8050 c. Thepockets 8060 a-c are arranged in a herringbone arrangement along thestaple-forming undersurface 8230 of the anvil 8200. In at least oneinstance, the pockets 8060 a-c on the opposing side of the slot 8226 canform a mirror image reflection of the pockets 8060 a-c on the first sideof the longitudinal slot 8226. In other instances, the arrangement ofpockets 8060 in the staple-forming undersurface 8230 can be asymmetricalrelative to the slot 8226 and, in certain instances, the anvil 8200 maynot include the longitudinal slot 8226. In various instances, thepockets 8060 can be arranged in less than or more than three rows oneach side of the slot 8226. Pockets 8060 a-c may comprise, for example,pockets 6060 described herein or they may comprise other pocketsincluding any of the other pocket configurations disclosed herein. Eachfirst pocket 8060 a lies along a corresponding first pocket axis FPAthat is transverse to the longitudinal axis LA. Each second pocket 8060b lies along a corresponding second pocket axis SPA that is transverseto the longitudinal axis LA as well as the first pocket axes FPA. Eachthird pocket 8060 c lies along a corresponding third pocket axis TPAthat is transverse to the longitudinal axis LA as well as to the secondpocket axes SPA. The third pocket axes TPA may be parallel with thefirst pocket axes FPA.

In the example depicted in FIG. 60, the anvil 8200 includes a pluralityof tissue stabilization features 8280 that are arranged in two rows 8270a, 8270 b on a first side of the longitudinal slot 8226. The first row8270 a is an inner row and includes a plurality of inner or first tissuestabilization cavities 8282 a-e therein that are each arranged on acorresponding first stabilization axis FSA that is transverse to thelongitudinal axis LA. Thus, the first stabilization cavities 8282 a-eare parallel to each other and each first stabilization axis FSA may beparallel to the first pocket axes FPA. The first stabilization cavities8282 a-e substantially occupy each non-forming surface portion 8240extending between adjacent first pockets 8060 a and corresponding secondpocket 8060 b as shown.

The second row 8270 b is an outer row and includes a plurality of outeror second tissue stabilization cavities 8282 f-i therein that are eacharranged on a corresponding second stabilization axis SSA that istransverse to the longitudinal axis LA and parallel with third pocketaxes TPA of a line of third pockets 8060 c. Thus, the secondstabilization cavities 8282 f-i are parallel to each other and eachthird pocket axis TPA. The second stabilization cavities 8282 a-esubstantially occupy each non-forming surface portion 8240 extendingbetween adjacent third pockets 8060 c and corresponding second pocket8060 b as shown.

In certain instances, each tissue stabilization cavity 8282 a-i has aplanar bottom 8284 and vertical side walls 8286 extending therefrom. Thetissue stabilization cavities 8282 a-i may be as deep as the pockets8060 a-c. The tissue stabilization cavities 8282 a-i may be deeper thanpockets 8060 a-c or they may be shallower than pockets 8060 a-c. Instill other configurations, some of the tissue stabilization cavities8282 a-i may be deeper than pockets 8060 a-c and other tissuestabilization cavities 8282 a-i may be shallower than pockets 8060 a-cin the same anvil 8200. The tissue stabilization cavities 8282 a-i mayhave the same perimetrical shape as the pockets 8060 a-c or they mayhave a perimetrical shape that differs from the perimetrical shape ofthe pockets 8060 a-c. The tissue stabilization cavities 8282 a-i may bedistinguishable from the pockets 8060 a-c in that the tissuestabilization cavities 8282 a-i have an enclosed bottom 8284. In onearrangement, the bottom 8284 is planar. However, in other arrangements,the enclosed bottom 8284 may not be planar. While the tissuestabilization cavities 8282 a-i may be designed to receive adjacenttissue therein during the clamping and stapling process, the enclosedbottom 8284 and smooth interior wall or walls 8286 prevent the tissuefrom becoming hung up and or trapped which could lead to tissue damagewhen the tissue is removed from the end effector. Each of the first andsecond stabilization axes FSA, SSA is transverse to the longitudinalaxis LA. During the stapling process, when the anvil 8200 gets pivotedclosed onto the target tissue to clamp the target tissue between thestaple-forming under surface 8230 of the anvil 8200 and the staplecartridge in the end effector, corresponding portions of the targettissue will enter the tissue stabilization cavities 8282 a-i which willhelp to minimize shifting or rolling of the target tissue as the knifeor firing member is advanced through the anvil 8200. The angledorientation of the tissue stabilization cavities 8282 a-i relative tothe direction of the knife (along the longitudinal axis LA) may serve tofurther stabilize the tissue during cutting. In addition, because someof the target tissue is able to enter the stabilization cavities, theanvil 8200 may be able to assume a closer position relative to thecartridge during firing and thereby reduce an amount of bending stressnormally experienced by the anvil. Such advantage may also result inlower closure and firing forces being needed during the closing andfiring processes.

Anvils that are configured for use in surgical stapling applications maybe formed using various manufacturing techniques and methods. Oneprevious manufacturing method for fabricating surgical stapler anvilscomprises the process of “coining”. “Coining” is a form of precisionstamping in which the anvil material is subjected to sufficiently highstress to induce plastic flow on the surface of the material. Coining iscommonly accomplished using a gear driven press, a hydraulic press or amechanical press. Coining typically requires higher tonnage presses thanare typically used in conventional stamping processes because theworkpiece is plastically deformed and not actually cut. Although coininghas been an effective way to form staple-forming pockets in thestaple-forming undersurface of an anvil, it can result in the creationof some undesirable characteristics in the finished anvil.

In various previous anvil fabrication methods where coining is employed,the anvil raw material, which may comprise a metal material such asstainless steel or the like, is typically initially extruded or rolledinto an initial blank or body. The anvil body can then be machined usingvarious conventional machining techniques so as to initially form planarforming surfaces on each size of an elongate slot formed in the body.Once the body has been machined so that the forming surfaces are flat,the forming pockets are then coined in the forming surfaces in a desiredpattern.

FIG. 61 depicts a portion of a previous anvil 8300 in cross-section.This previous anvil comprises an anvil body 8310 that consists of leftand right staple-forming undersurfaces 8330L, 8330R that are separatedby an elongate slot 8326. The anvil body portion 8310 may be extruded orrolled out of 304 stainless steel or similar material. The elongate slot8326 and the anvil forming surfaces 8330L, 8330R are commonly machinedflat prior to the formation of the staple-forming pockets 8360 therein.An anvil cover 8390, which may be manufactured from 17-4 PH stainlesssteel, is welded to the body portion 8310 at joints 8392 with welds8394. FIG. 62 comprises a photograph taken using a scanning electronmicroscope of a weld joint 8392 of a previous anvil 8300 showing thedifferent grain structures of the anvil body 8310 and anvil cover 8390as well as of the weld 8394.

FIG. 63 depicts a portion of the anvil 8300 in cross-section prior tothe formation of the staple-forming pockets 8360 therein using aprevious coining method. As can be seen in that Figure, a formingsurface 8330R has been machined flat on one side of the elongate slot8326 that was also machined into the anvil body 8310 using conventionalmachining methods and techniques. The Figure illustrates a crystallinestructure 8312 of the anvil body material prior to the coiningoperation. The desired final staple-forming pocket 8360 configuration isillustrated in phantom lines. FIG. 64 illustrates the anvil body 8310after the staple-forming pocket 8360 has been coined therein. Thecoining operation consists of striking the forming surface 8330 with adie (not shown) which results in high material displacement which leadsto high material density (lines 8314) around the formed pocket 8360.FIG. 65 is a photograph of a cross-section of a portion of a previousanvil 8300 using a scanning electron microscope. The photographillustrates the extensive grain deformation and occlusions formed belowthe pockets 8360 as a result of the coining process.

FIG. 66 is a photograph taken of a portion of the previous anvil body8310 that is below a pocket 8360 after the coining process. FIGS. 67 and68 comprise photographs of the region below the coined pocketsillustrating inclusions 8397 formed in the material. These elongatenon-metallic inclusions 8397 are typically found in a wrought product.The directionality of the inclusions indicates that the material wasrolled or extruded. FIG. 69 comprises a higher magnification photographof a portion of a previous anvil 8300 in an area that was not coinedillustrating non-metallic inclusions 8398 and 8399 therein.

In addition to the previous coining process employed to form theprevious anvil 8300, once the forming pockets 8360 have been coined intothe forming surfaces 8330L, 8330R, the forming surfaces 8330L, 8330R andpockets 8360 may be brushed and ultrasonically cleaned to remove anylubrication and debris resulting from the coining process. FIG. 70comprises a photograph of a portion of the previous anvil 8300 after thecleaning processes. FIGS. 71 and 72 are photographs of bottom portionsof one of the forming pockets 8360 showing some of the metal smearing8361 that results from the coining process. As illustrated in FIGS.65-69 and 71 and 72, the above-described previous method of anvilmanufacturing may result in the formation of an anvil with undesirableinclusions in the anvil body which may weaken the anvil. Such processmay also result in the formation of staple-forming pockets that haveundesirably rough forming surfaces.

FIGS. 73-77 illustrate a method 8400 that may avoid some of theaforementioned problems commonly encountered when using previous anvilmanufacturing methods. In at least one configuration, the method 8400involves employing a process of metal injection molding (“MIM”) forforming an anvil body portion 8510 of an anvil 8500. MIM is a metalworking process in which finely-powdered metal is mixed with bindermaterial to create a “feedstock” (action 8402) that is shaped andsolidified into an anvil body 8510 using injection molding (8404). Aftermolding (8404), the anvil body 8510 undergoes conditioning operations toremove the binder and to densify the powders (debinding—8406). In atleast one configuration, the MIM process is used to create an anvil body8510 that has a plurality of “preliminary” staple-forming pocketconfigurations that have a “near net configuration” or a near net“geometry”, which differs from “final” desired pocket configuration orgeometry. For example, a preliminary pocket configuration may have asimilar shape as a final pocket configuration, but the final pocketconfiguration may comprise a larger and deeper void or pocket in theanvil body.

More specifically and with reference to FIG. 74, a portion of the anvilbody 8510 is shown after the anvil body 8510 has been formed using theMIM process (for example—actions 8402, 8404, 8406). In at least onearrangement, the anvil body 8510 has been initially formed with a flator planar staple-forming undersurface 8430 that has a plurality ofstaple-forming pockets 8560P formed therein that each have a “near net”shape or geometry or a “pre-shape”. In the example illustrated incross-section in FIG. 74, a “pre-formed” pocket 8560P includes a bottomsurface 8532P and two sloping side walls 8534P. The sloping sidewalls8534P form a pocket opening that has a preliminary width “PW” (incross-section). The bottom surface 8532P is located a preliminary depth“PD” from the staple-forming undersurface 8530. The desired final pocketshape 8360F is illustrated in segmented lines in FIG. 74. Once the anvilbody 8510 has been formed with the “pre-shaped” or “preliminary” pockets8360P, a coining process 8408 is employed to form the final formingpockets 8560F therein.

FIG. 75 illustrates a final forming pocket 8560F that has been formedinto the anvil body 8510. As can be seen in that Figure, the finalforming pocket 8560F includes a final bottom surface 8532F and twosloping sidewalls 8534F that define a pocket opening with a final width“FW”. The final bottom surface 8532F is located a final depth “FD” fromthe forming surface 8530. In the illustrated example, FW>PW and FD>PD.The cross-sectional shape of the forming pockets 8560P, 8560F depictedin FIGS. 74 and 75 are for illustrative purposes only and should not belimiting. The shapes of the pockets may vary with a final forming pocketbeing larger than the preliminary or pre-shaped forming pocket. Whilethe geometric shape of the final pocket 8560F may be similar to thepreformed pocket 8560P geometry, the final pocket 8560F will be largerthan the preformed pocket 8560P due to the coining process 8408. Inaddition, the pre-surface finish 8536P of the pre-formed pocket 8560P asa result of the MIM processes 8402. 8404, 8406, may be different fromthe final surface finish 8536F of the final pocket 8560F as a result ofthe coining process 8408. For example, the pre-surface finish 8536P maybe rougher than the final surface finish 8536F. FIG. 76 illustrates apreliminary or pre-shaped forming pocket 8560P that has beenpreliminarily formed using the MIM process. As can be seen in thatFigure, the surface finish 8536P of the forming pocket 8560P can besomewhat rougher than the final surface finish 8536F of the finalforming pocket 8560F (shown in FIG. 77) that is formed by the finalcoining process 8408. Because the preliminary or pre-shaped formingpockets have a pre-shape, the coining process is performed with a lowerforce than is typically used in previous coining operations. Such lowercoining force results in less material displacement and lowercompression than is typically experienced when using previous coiningoperations. In an alternative method, the coining process may bereplaced with a forging process. In this alternative method, forexample, after the anvil body has been formed with previous or preformedforming pockets using the above-described MIM process, the anvil bodymay be heated while it is struck with a forging die that is configuredto form the final forming pockets therein in manner described above.

FIGS. 78-82 illustrate an alternative use of the method 8400′ to formstaple-forming pockets 8560F′ in the anvil body material 8510. In thismethod 8400′, the preformed pocket configuration 8560P′ is formed with arelatively final shape and size, except for the provision of a stapleleg guidance groove also referred to as a “staple-forming path” 8570therein. The staple-forming path 8570 is coined into the bottom surface8532P of the pocket (action 8408′). The staple-forming path 8570 is onlycoined in the bottom 8532P of the pocket 8560P′ to form the pocket8560F′. See FIGS. 81 and 82. As can be seen in FIG. 82, thestaple-forming path 8570 is smoother than the surrounding surfacesformed by the MIM process. That is, the surface finish 8572F′ of thestaple-forming path 8570 is smoother than the surface finish 8536P′ ofthe remaining walls of pocket 8560F′. The staple-forming path 8570 isalso harder and denser than the MIM formed portions due to thecompression attained from coining. However, the problems associated withprevious coining operations are less likely to occur due to the lowerforces and compressions attained using the method 8400′.

Another anvil manufacturing method 8600 is depicted in FIG. 83. Method8600 involves forming the anvil body 8510 using liquid metal orVitreloy. The liquid metal process is employed to form the anvil body8510 with the anvil pockets 8560P in their near net shape (action 8602).As with method 8600, a coining process 8604 is used to provide theforming pockets 8560F with their final configurations. FIG. 84 depicts amethod 8600′ that comprises using the liquid metal process to form theanvil body 8510 with pockets that have their final shape (action 8602′)and then coining the staple-forming path 8570 into each pocket (action8604′). As with the process 8400 described above, the final formingpockets 8560F may have a similar geometric shape as the pre-formed ornear net forming pockets 8560P with the final forming pockets 8560Fbeing larger and deeper.

Another anvil manufacturing method 8700 is depicted in FIG. 85. Method8700 comprises extruding or rolling an initial blank or body that issized and shaped to be machined into a desired final configuration(action 8702). The anvil body is machined using various conventionalmachining techniques so as to initially form planar forming surfaces oneach size of the elongate slot. In addition, in this arrangement, themethod involves machining the pre-formed or initial pockets 8560P intothe planar forming surfaces (action 8704). The pre-formed pocket 8560Pmay be similar to the preformed pocket configurations such as thosedepicted in FIG. 74, for example. Thereafter, the final pocketconfigurations 8560F are formed by coining to attain the configurationsuch as that depicted in FIG. 75 (action 8706). In using method 8700,however, the anvil body is not created using MIM or liquid metal.Instead, the anvil body material may be extruded or rolled and thenmachined. However, because the coining forces needed are lower than thepreviously used coining methods, the compression and materialdisplacement will be lower. FIG. 86 depicts a method 8700′ thatcomprises extruding or rolling an initial blank or body that is sizedand shaped to be machined into a desired final configuration (action8702). The anvil body is machined using various conventional machiningtechniques so as to initially form the pockets into the planar formingsurfaces on each size of the elongate slot. Coining (action 8706′) isthen employed to coin the staple-forming pass 8570 into each pocket.

FIG. 87 depicts another method 8800 that employs the action 8402 tocreate the feedstock. The anvil body in this method is injection molded(action 8404′) in final form, but without any anvil pockets formedtherein. The anvil body is then conditioned (action 8406). The preformedpockets 8560P are then machined into the anvil body (action 8808). Thefinal pockets 8560F are then formed into the anvil body by coining(action 8810). FIG. 88 depicts another method 8800′ that is similar tomethod 8800, except that the pockets are machined with their finalconfiguration (action 8808′). The staple-forming paths are then coinedinto the bottom of each pocket (action 8810′).

FIG. 89 depicts another method 8900 wherein the anvil body is formedusing liquid metal (action 8902). Near-net pockets are then machinedinto the anvil body (action 8904). The final pocket configurations arethen coined into the anvil body (action 8906). FIG. 90 depicts anothermethod 8900′ that is similar to method 8900, except that the pockets aremachined with their final configuration (action 8904′). Thestaple-forming paths are then coined into the bottom of each pocket(action 8906′). In alternative arrangements, the preformed pockets 8560Pmay be formed in the anvil body 8510 using electrochemical machining(ECM). ECM is a method of removing metal by an electrochemical process.ECM is similar to electrical discharge machining (EDM) in that a highcurrent is passed between an electrode and the part through anelectrolytic material removing process having a negatively chargedelectrode (cathode), a conductive fluid (electrolyte) and a conductiveworkpiece (anode). The ECM cutting tool is guided along the desired pathclose to the work, but without touching the piece. Once the preformedpockets are formed in the anvil body using the ECM process, the finalpocket form or the staple-forming path is coined into each pocket.

By forming the anvil body using the MIM process or the liquid metalprocess, the irregularities and inclusions often encountered inprocesses wherein the anvil body is extruded or rolled may be avoided.By preforming the pockets in the anvil body using the various methodsdescribed herein prior to coining enables lower coining forces to beemployed when forming the final pocket configuration or staple-formingpath. Such lower coining forces result in lower compression and lessmaterial displacement and consequently a reduction in the irregularitiesand occlusions commonly encountered when employing previous anvilfabrication methods.

Turning now to FIGS. 91-93, an anvil 9000 is illustrated that may besimilar to the anvils described herein, except that anvil 9000 includesa deformable anvil tip 9010. The anvil 9000 comprises an anvil body 9002that includes a staple-forming undersurface generally designated as 9004through which an elongate slot 9006 passes. The staple-formingundersurface 9004 defines ledges 9008, 9010 that are located on eachside of the elongate slot 9006 within the anvil body 9002 for slidingengagement by protrusions formed on or attached to a knife of firingmember that is configured to pass through the slot 9006 during thestaple firing and tissue cutting processes. As can be seen in FIGS.91-93, the deformable anvil tip 9050 is attached to a distal end 9020 ofthe anvil body 9002.

In the illustrated arrangement, the anvil body 9002 may be fabricatedfrom a first material such as a first metal material which may comprise,for example, stainless steel, titanium, etc. The deformable anvil tip9050 may be fabricated from a second material that is more flexible anddeformable than the first material, for example. The second material maycomprise a plastic material. In at least one arrangement, the deformableanvil tip 9050 may be fabricated from aa thermoset plastic that does notremold under heat, for example. In the example depicted in FIGS. 91-93,the deformable anvil tip 9050 includes an attachment portion 9052 thatcomprises a first flexible attachment assembly 9054. In one arrangement,the first flexible attachment assembly 9054 is T-shaped when viewed fromabove. The T-shaped first attachment assembly 9054 is configured to beslidably received within a T-shaped slot arrangement 9022 that is formedin the distal end 9020 of the anvil body 9002. The T-shaped firstattachment assembly 9054 is configured to be inserted into the slot 9022in an insertion direction ID that is transverse to an anvil axis ANAthat is defined by the anvil body 9002.

Still referring to FIGS. 91-93, the T-shaped first attachment assembly9054 includes a slotted through hole 9056 that defines a right flexibleattachment tab 9058 and a left flexible attachment tab 9060. The rightflexible attachment tab 9058 and the left flexible attachment tab 9060are configured to be slidably received in corresponding portions of theT-shaped slot arrangement 9022 in the insertion direction ID. Once thefirst attachment assembly 9054 has been inserted into the T-shaped slot9022 in the distal end 9020 of the anvil body 9002, a second attachmentmember 9070 is inserted into the slotted through hole 9056 in the firstattachment assembly 9054. In at least one arrangement, the secondattachment member 9070 comprises a body 9072 that includes a transversetop member 9074. The body 9072 comprises a retention feature or featuresin the form of deformable threads or shoulders 9076 formed thereon. Toaffix the deformable anvil tip 9050 to the anvil body 9002, the firstattachment assembly 9054 is inserted into the T-shaped slot arrangement9022 in the insertion direction and seated in the bottom thereof againstthe ledges 9008, 9010. The body 9072 of the second attachment member9070 is inserted into the slotted through hole 9056 in the firstattachment assembly 9054 in the insertion direction ID. In at least onearrangement, the slotted through hole 9056 is sized relative to the bodyportion 9072 of the second attachment member 9070 so as to cause theflexible attachment tabs 9058, 9060 to flex laterally outward in lateralattachment directions LAD into lateral retaining engagement with thecorresponding portions of the T-shaped slot 9022. Once the secondattachment member 9070 has been inserted into the slotted through hole9056 in the first attachment assembly 9054, the deformable shoulders9076 thereon retain the second member 9070 in retaining engagement andprevent its removal from the through hole 9056. In one arrangement, thesecond attachment member 9070 is inserted under pressure into theslotted through hole 9056. In another arrangement, the second attachmentmember 9070 is heated and inserted under pressure (heat staking) suchthat once the second attachment member 9070 has been inserted and seatedinto the slotted through hole 9056, the shoulders 9076 are permanentlydeformed to retain the second attachment member 9070 in retainingposition.

As can also be seen in FIGS. 91-93, the anvil 9000 may comprise an anvilcap 9080 that is sized to cover the elongate slot 9006 in the anvil body9002. The anvil cap 9080 may be fabricated from the same materialcomprising the anvil body 9002 and be welded to the anvil body 9002after the deformable anvil tip 9050 has been installed in theabove-described manner. The anvil cap 9080 comprises a distal end 9082that is configured to be received in a cavity 9062 provided in theattachment portion 9052 of the deformable anvil tip 9050. Sucharrangement further retains the second attachment member 9070 inposition. Once the deformable anvil tip 9050 has been attached to theanvil body 9002, a distal end portion 9051 of the anvil tip 9050 anglesbelow the staple-forming undersurface 9004 of the anvil body 9002. SeeFIG. 92.

Turning next to FIGS. 94 and 95, an anvil 9100 is shown that is similarto anvil 9000 described above, except for the following differences. Theanvil 9100 comprises an anvil body 9102 that includes a staple-formingundersurface generally designated as 9104 through which an elongate slot9106 passes. The staple-forming undersurface 9104 serves to form ledges9108, 9110 on each side of the elongate slot 9106 within the anvil body9102 for sliding engagement by protrusions formed on or attached to aknife of firing member that passes through the slot 9106 during thestaple firing and tissue cutting processes. As can be seen in FIGS. 94and 95, the anvil 9100 comprises a deformable anvil tip 9150 that isattached to a distal end 9120 of the anvil body 9102.

In the illustrated arrangement, the anvil body 9102 may be fabricatedfrom a first material such as a first metal material which may comprisestainless steel, titanium, etc. The deformable anvil tip 9050 may befabricated from a second material that is more flexible and deformablethan the first material and comprise, for example, a plastic material.In at least one arrangement, the deformable anvil tip 9050 is fabricatedfrom a thermoset plastic that does not remold under heat, for example.In the example depicted in FIGS. 94 and 95, the deformable anvil tip9050 includes an attachment portion 9152 that comprises a first flexibleattachment assembly 9154. In one arrangement, the first flexibleattachment assembly 9154 is T-shaped when viewed from above. TheT-shaped first attachment assembly 9154 is configured to be slidablyreceived within a T-shaped slot arrangement 9122 that is formed in thedistal end 9120 of the anvil body 9102. As can be most particularly seenin FIG. 94, the T-shaped slot arrangement 9122 comprises two cavities9124 formed through the staple-forming undersurface 9104. Unlike anvil9000 described above, the arrangement T-shaped first attachment assembly9154 is configured to be inserted into the slot 9122 from the bottom ofthe staple-forming undersurface 9104 in an insertion direction ID_(B)that is transverse to an anvil axis ANA that is defined by the anvilbody 9102.

Still referring to FIGS. 94 and 95, the T-shaped first attachmentassembly 9154 includes a slotted through hole 9156 that defines a rightflexible attachment tab 9158 and a left flexible attachment tab 9160.The right flexible attachment tab 9158 and the left flexible attachmenttab 9160 are configured to be slidably received in the correspondingcavities 9124 of the T-shaped slot arrangement 9122 in the insertiondirection ID_(B). Once the first attachment assembly 9154 has beeninserted into the T-shaped slot 9122 in the distal end 9120 of the anvilbody 9102, a second attachment member 9170 is inserted into the slottedthrough hole 9156 in the first attachment assembly 9154. In at least onearrangement, the second attachment member comprises a body 9172 thatincludes a transverse top member 9174. The body 9172 has a retentionfeature or features in the form of deformable threads or shoulders 9176formed thereon. To affix the deformable anvil tip 9150 to the anvil body9102, the first attachment assembly 9154 is inserted into the T-shapedslot arrangement 9122 in the insertion direction ID_(B) and seated inthe cavities 9124. The body 9172 of the second attachment member 9170 isinserted into the slotted through hole 9156 in the first attachmentmember 9154 in the insertion direction ID_(B). In at least onearrangement, the slotted through hole 9156 is sized relative to the bodyportion 9172 of the second attachment member 9170 so as to cause theflexible attachment tabs 9058, 9160 to flex laterally outward in lateralattachment directions into lateral retaining engagement with thecorresponding cavities 9124. Once the second attachment member 9170 hasbeen inserted into the slotted through hole 9156 in the first attachmentassembly 9154, the deformable shoulders 9176 thereon retain the secondmember 9170 in retaining engagement and prevent its removal from thethrough hole 9156. In one arrangement, the second attachment member 9170is inserted under pressure into the slotted through hole 9156. Inanother arrangement, the second attachment member 9170 is heated andinserted under pressure (heat staking) such that once the secondattachment member 9170 has been inserted and seated into the slottedthrough hole 9156, the shoulders 9176 are permanently deformed to retainthe second attachment member 9170 in position. In the illustratedexample, tissue-gripping features or nodules 9178 are formed on the topportion 9174 of the second attachment member 9170 to aid in grippingtissue with the anvil 9100. As can also be seen in FIG. 94, the anvil9100 may comprise an anvil cap 9180 that is sized to cover the slot 9106in the anvil body 9102. The anvil cap 9180 may be fabricated from thesame material comprising the anvil body 9102 and be welded to the anvilbody 9102. Once the deformable anvil tip 9150 has been attached to theanvil body 9102, a distal tip 9151 of the anvil tip 9150 angles belowthe staple-forming undersurface 9104 of the anvil body 9102. See FIG.95. In one arrangement, the deformable anvil tip 9150 may have aconstant width throughout its entire length and also have a relativesquared-off distal end portion.

Turning next to FIGS. 96 and 97, an anvil 9200 is shown that comprisesan anvil body 9202 that includes a staple-forming undersurface generallydesignated as 9204. The anvil 9200 includes a deformable anvil tip 9250that is attached to a distal end 9220 of the anvil body 9202. In theillustrated arrangement, the anvil body 9202 may be fabricated from afirst material which may comprise a first metal material such asstainless steel, titanium, etc. The deformable anvil tip 9050 may befabricated from a second material that is more flexible and deformablethan the first material and may comprise, for example, a plasticmaterial. In at least one arrangement, the deformable anvil tip 9250 isfabricated from a thermoset plastic that does not remold under heat, forexample. In the example depicted in FIGS. 96 and 97, a distallyextending attachment member or lug assembly 9230 is formed on the distalend 9020 of the anvil body 9202. As can be seen in FIG. 96, in onearrangement, the attachment assembly 9230 comprises a first planarportion 9232 that extends from an arcuate molding shoulder 9225 thatprotrudes from the distal end 9220 of the anvil body 9202. A segmentedlug portion 9234 is attached to the first planar portion 9232 such thatit extends transversely therefrom. The planar attachment portion 9232may additionally have a hole 9236 therein to facilitate flow of theflexible tip material therethrough when the anvil tip 9250 is moldedthereto. As may be common with various anvil assemblies, the anvil bodythereof may be coated with a lubricious material to facilitate improvedstaple formation as well as insertion through trocar cannulas, etc. Inthe illustrated example, the portion of the anvil body 9202 that isproximal to the distal end position 9220 may be lubricated in suchmanner, for example. However, the attachment assembly 9230 may be etchedto remove any lubrication therefrom and improve the adhesion of theovermolded deformable anvil tip 9250 to the anvil body 9202. The etchingprocess may create a frictional adhesion surface for the second materialto better adhere to. In other arrangements, for example, the attachmentassembly may be covered during the application of the lubrication to theanvil body to prevent the lubrication medium from being applied to theattachment assembly. Once the deformable anvil tip 9250 has been moldedto the anvil body 9202, a distal end portion 9251 of the anvil tip 9250angles below the staple-forming undersurface 9204 of the anvil body9202. In one arrangement, the deformable anvil tip 9250 may have aconstant width throughout its entire length and also have a relativesquared-off distal end portion.

Referring now to FIGS. 98 and 99, another anvil arrangement 9300comprises an anvil body 9302 that includes a staple-forming undersurfacegenerally designated as 9304 through which an elongate slot 9306 passes.As can be seen in FIGS. 98 and 99, the anvil 9300 includes a deformableanvil tip assembly 9350 that is attached to a distal end 9320 of theanvil body 9302.

In the illustrated arrangement, the anvil body 9302 may be fabricatedfrom a first material which may comprise, for example, a first metalmaterial such as stainless steel, titanium, etc. A first portion 9351 ofthe deformable anvil tip assembly 9350 may be fabricated from a secondmaterial that is more flexible and deformable than the first materialand may comprise a plastic material, for example. In at least onearrangement, the deformable anvil tip assembly 9350 comprises a firsttip portion 9351 that comprises a thermoset plastic that does not remoldunder heat, for example. In the example depicted in FIGS. 98 and 99, thedeformable anvil tip assembly 9350 includes an attachment portion 9352that comprises a proximally extending attachment tab 9354. In onearrangement, the attachment tab 9354 is configured to be received in acorrespondingly shaped cavity 9322 that is formed in the distal end 9320of the anvil body 9302. The attachment tab 9354 is retained within thecavity 9322 by an anvil cap 9380 that that is sized to cover the slot9306 in the anvil body 9302. When the anvil cap 9380 is attached to theanvil body 9302, the anvil cap 9380 retains the attachment tab 9354 inthe cavity 9322 to affix the deformable anvil tip assembly 9350 to theanvil body 9302. In addition, the first portion 9351 of the deformableanvil tip assembly 9350 may also be provided with a slot 9355 that isconfigured to receive a tip insert 9390 therein. In one arrangement, thetip insert 9390 is fabricated from a material that is more rigid thanthe second material from which the first tip portion is fabricated. Inone example, first portion 9351 of the anvil tip assembly 9350 may bemolded to the tip insert 9390. In some arrangements, the tip insert 9390may be additionally welded or attached to the anvil body 9302. Once thedeformable anvil tip assembly 9350 has been attached to the anvil body9302, a distal end portion 9353 of the anvil tip assembly 9350 anglesbelow the staple-forming undersurface 9304 of the anvil body 9302. SeeFIGS. 98 and 99. In one arrangement, the anvil tip assembly 9350 mayhave a constant width throughout its entire length and also have arelative squared-off distal end portion.

Many of the surgical instrument systems described herein are motivatedby an electric motor; however, the surgical instrument systems describedherein can be motivated in any suitable manner. In various instances,the surgical instrument systems described herein can be motivated by amanually-operated trigger, for example. In certain instances, the motorsdisclosed herein may comprise a portion or portions of a roboticallycontrolled system. Moreover, any of the end effectors and/or toolassemblies disclosed herein can be utilized with a robotic surgicalinstrument system. U.S. patent application Ser. No. 13/118,241, entitledSURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENTARRANGEMENTS, now U.S. Pat. No. 9,072,535, for example, disclosesseveral examples of a robotic surgical instrument system in greaterdetail.

The surgical instrument systems described herein have been described inconnection with the deployment and deformation of staples; however, theembodiments described herein are not so limited. Various embodiments areenvisioned which deploy fasteners other than staples, such as clamps ortacks, for example. Moreover, various embodiments are envisioned whichutilize any suitable means for sealing tissue. For instance, an endeffector in accordance with various embodiments can comprise electrodesconfigured to heat and seal the tissue. Also, for instance, an endeffector in accordance with certain embodiments can apply vibrationalenergy to seal the tissue.

The entire disclosures of:

-   U.S. Pat. No. 5,403,312, entitled ELECTROSURGICAL HEMOSTATIC DEVICE,    which issued on Apr. 4, 1995;-   U.S. Pat. No. 7,000,818, entitled SURGICAL STAPLING INSTRUMENT    HAVING SEPARATE DISTINCT CLOSING AND FIRING SYSTEMS, which issued on    Feb. 21, 2006;-   U.S. Pat. No. 7,422,139, entitled MOTOR-DRIVEN SURGICAL CUTTING AND    FASTENING INSTRUMENT WITH TACTILE POSITION FEEDBACK, which issued on    Sep. 9, 2008;-   U.S. Pat. No. 7,464,849, entitled ELECTRO-MECHANICAL SURGICAL    INSTRUMENT WITH CLOSURE SYSTEM AND ANVIL ALIGNMENT COMPONENTS, which    issued on Dec. 16, 2008;-   U.S. Pat. No. 7,670,334, entitled SURGICAL INSTRUMENT HAVING AN    ARTICULATING END EFFECTOR, which issued on Mar. 2, 2010;-   U.S. Pat. No. 7,753,245, entitled SURGICAL STAPLING INSTRUMENTS,    which issued on Jul. 13, 2010;-   U.S. Pat. No. 8,393,514, entitled SELECTIVELY ORIENTABLE IMPLANTABLE    FASTENER CARTRIDGE, which issued on Mar. 12, 2013;-   U.S. patent application Ser. No. 11/343,803, entitled SURGICAL    INSTRUMENT HAVING RECORDING CAPABILITIES; now U.S. Pat. No.    7,845,537;-   U.S. patent application Ser. No. 12/031,573, entitled SURGICAL    CUTTING AND FASTENING INSTRUMENT HAVING RF ELECTRODES, filed Feb.    14, 2008;-   U.S. patent application Ser. No. 12/031,873, entitled END EFFECTORS    FOR A SURGICAL CUTTING AND STAPLING INSTRUMENT, filed Feb. 15, 2008,    now U.S. Pat. No. 7,980,443;-   U.S. patent application Ser. No. 12/235,782, entitled MOTOR-DRIVEN    SURGICAL CUTTING INSTRUMENT, now U.S. Pat. No. 8,210,411;-   U.S. patent application Ser. No. 12/235,972, entitled MOTORIZED    SURGICAL INSTRUMENT, now U.S. Pat. No. 9,050,083.-   U.S. patent application Ser. No. 12/249,117, entitled POWERED    SURGICAL CUTTING AND STAPLING APPARATUS WITH MANUALLY RETRACTABLE    FIRING SYSTEM, now U.S. Pat. No. 8,608,045;-   U.S. patent application Ser. No. 12/647,100, entitled MOTOR-DRIVEN    SURGICAL CUTTING INSTRUMENT WITH ELECTRIC ACTUATOR DIRECTIONAL    CONTROL ASSEMBLY, filed Dec. 24, 2009; now U.S. Pat. No. 8,220,688;-   U.S. patent application Ser. No. 12/893,461, entitled STAPLE    CARTRIDGE, filed Sep. 29, 2012, now U.S. Pat. No. 8,733,613;-   U.S. patent application Ser. No. 13/036,647, entitled SURGICAL    STAPLING INSTRUMENT, filed Feb. 28, 2011, now U.S. Pat. No.    8,561,870;-   U.S. patent application Ser. No. 13/118,241, entitled SURGICAL    STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS,    now U.S. Pat. No. 9,072,535;-   U.S. patent application Ser. No. 13/524,049, entitled ARTICULATABLE    SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, filed on Jun. 15,    2012; now U.S. Pat. No. 9,101,358;-   U.S. patent application Ser. No. 13/800,025, entitled STAPLE    CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013,    now U.S. Pat. No. 9,345,481;

U.S. patent application Ser. No. 13/800,067, entitled STAPLE CARTRIDGETISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013, now U.S. PatentApplication Publication No. 2014/0263552;

-   U.S. Patent Application Publication No. 2007/0175955, entitled    SURGICAL CUTTING AND FASTENING INSTRUMENT WITH CLOSURE TRIGGER    LOCKING MECHANISM, filed Jan. 31, 2006; and-   U.S. Patent Application Publication No. 2010/0264194, entitled    SURGICAL STAPLING INSTRUMENT WITH AN ARTICULATABLE END EFFECTOR,    filed Apr. 22, 2010, now U.S. Pat. No. 8,308,040, are hereby    incorporated by reference herein.

Although various devices have been described herein in connection withcertain embodiments, modifications and variations to those embodimentsmay be implemented. Particular features, structures, or characteristicsmay be combined in any suitable manner in one or more embodiments. Thus,the particular features, structures, or characteristics illustrated ordescribed in connection with one embodiment may be combined in whole orin part, with the features, structures or characteristics of one or moreother embodiments without limitation. Also, where materials aredisclosed for certain components, other materials may be used.Furthermore, according to various embodiments, a single component may bereplaced by multiple components, and multiple components may be replacedby a single component, to perform a given function or functions. Theforegoing description and following claims are intended to cover allsuch modification and variations.

The devices disclosed herein can be designed to be disposed of after asingle use, or they can be designed to be used multiple times. In eithercase, however, a device can be reconditioned for reuse after at leastone use. Reconditioning can include any combination of the stepsincluding, but not limited to, the disassembly of the device, followedby cleaning or replacement of particular pieces of the device, andsubsequent reassembly of the device. In particular, a reconditioningfacility and/or surgical team can disassemble a device and, aftercleaning and/or replacing particular parts of the device, the device canbe reassembled for subsequent use. Those skilled in the art willappreciate that reconditioning of a device can utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

The devices disclosed herein may be processed before surgery. First, anew or used instrument may be obtained and, when necessary, cleaned. Theinstrument may then be sterilized. In one sterilization technique, theinstrument is placed in a closed and sealed container, such as a plasticor TYVEK bag. The container and instrument may then be placed in a fieldof radiation that can penetrate the container, such as gamma radiation,x-rays, and/or high-energy electrons. The radiation may kill bacteria onthe instrument and in the container. The sterilized instrument may thenbe stored in the sterile container. The sealed container may keep theinstrument sterile until it is opened in a medical facility. A devicemay also be sterilized using any other technique known in the art,including but not limited to beta radiation, gamma radiation, ethyleneoxide, plasma peroxide, and/or steam.

While this invention has been described as having exemplary designs, thepresent invention may be further modified within the spirit and scope ofthe disclosure. This application is therefore intended to cover anyvariations, uses, or adaptations of the invention using its generalprinciples.

1-10. (canceled)
 11. A method for forming an anvil of a surgicalstapler, said method comprising: forming an anvil body from a firstmaterial to include an attachment assembly protruding distally from adistal end of the anvil body; lubricating the anvil body with alubricant; removing the lubricant from the attachment assembly; andmolding a tip assembly onto the attachment assembly from a secondmaterial that differs from the first material.
 12. The method of claim11, wherein said molding a tip assembly comprises molding a tip assemblywith a first flexible attachment portion and a distal portion thatprotrudes at an angle from the first flexible attachment portion. 13.The method of claim 12, wherein said forming an anvil body comprisesforming an anvil body including a staple-forming undersurface andwherein said molding a tip assembly comprises molding a tip assemblywith a first flexible attachment portion and a distal portion thatprotrudes at an angle from the first flexible attachment portion suchthat the distal portion extends below the staple-forming undersurface.14. The method of claim 11, wherein said forming an anvil bodycomprises: forming a planar attachment portion extending distally from adistal end of the anvil body; and forming a segmented lug portion ontothe planar attachment portion such that the segmented lug portion istransverse to the planar attachment portion.
 15. The method of claim 11,wherein said removing the lubricant from the attachment assemblycomprises etching the attachment assembly with an etching medium.
 16. Amethod for fabricating an anvil of a surgical stapling device, saidmethod comprising: forming an anvil body from a first material, whereinthe anvil body includes a distal end with an opening therein andelongate slot; forming an anvil tip from a second material that differsfrom the first material and includes a proximally protruding attachmenttab; inserting the proximally protruding attachment tab into the openingin the distal end of the anvil body; and installing an anvil cap in theelongate slot to retain the proximally protruding attachment tab in theopening in the distal end of the anvil body.
 17. The method of claim 16,wherein said forming an anvil body comprises forming an anvil bodyincluding a staple-forming undersurface and wherein said forming ananvil tip comprises forming a tip assembly with a distal portion thatprotrudes at an angle from the attachment tab such that the distalportion extends below the staple-forming undersurface of the anvil body.18. The method of claim 16, further comprising attaching an insert thatis fabricated from an insert material that differs from said secondmaterial to the anvil tip.
 19. The method of claim 18, wherein saidinsert material comprises said first material.
 20. The method of claim18, wherein said attaching comprises molding the anvil tip from thesecond material onto the insert fabricated from the first material. 21.The method of claim 14, wherein said forming a planar attachment portionextending distally from a distal end of the anvil body further comprisesforming a hole through the planar attachment portion.
 22. The method ofclaim 21, wherein said molding a tip assembly onto the attachmentassembly from a second material that differs from the first material,comprises molding the second material such that at least some of thesecond material flows through the hole in the planar attachment portion.23. The method of claim 12, wherein said molding a tip assembly furthercomprises molding the distal portion with a constant width and asquared-off distal end.
 24. The method of claim 11, wherein said moldinga tip assembly onto the attachment assembly from a second material thatdiffers from the first material comprises molding the tip assembly froma thermoset plastic material that does not remold under heat.
 25. Amethod for forming an anvil of a surgical stapler, said methodcomprising: forming an anvil body from a first material, wherein theanvil body comprises: a proximal portion comprising a staple-formingundersurface; and an attachment assembly protruding distally from theproximal portion, and wherein said method further comprises: coveringthe attachment assembly with a removable covering; lubricating theproximal portion of the anvil body with a lubricant; removing theremoval covering from the attachment assembly; and molding a tipassembly onto the attachment assembly from a second material thatdiffers from the first material.
 26. The method of claim 25, whereinsaid molding a tip assembly comprises molding a tip assembly with afirst flexible attachment portion and a distal portion that protrudes atan angle from the first flexible attachment portion.
 27. The method ofclaim 25, wherein said molding a tip assembly comprises molding a tipassembly with a first flexible attachment portion and a distal portionthat protrudes at an angle from the first flexible attachment portionsuch that the distal portion extends below the staple-formingundersurface.
 28. The method of claim 25, wherein said forming an anvilbody comprises: forming a planar attachment portion extending distallyfrom a distal end of the proximal portion of the anvil body; and forminga segmented lug portion onto the planar attachment portion such that thesegmented lug portion is transverse to the planar attachment portion.29. The method of claim 28, wherein said forming a planar attachmentportion extending distally from a distal end of the proximal portion ofthe anvil body further comprises forming a hole through the planarattachment portion.
 30. The method of claim 29, wherein said molding atip assembly onto the attachment assembly from a second material thatdiffers from the first material, comprises molding the second materialsuch that at least some of the second material flows through the hole inthe planar attachment portion.
 31. The method of claim 26, wherein saidmolding a tip assembly further comprises molding the distal portion witha constant width and a squared-off distal end.
 32. The method of claim25, wherein said molding a tip assembly onto the attachment assemblyfrom a second material that differs from the first material comprisesmolding the tip assembly from a thermoset plastic material that does notremold under heat.